690 Enduro R Usa Manual

OWNER'S MANUAL 2009
690 Enduro R USA

ART. NO. 3211360en
DEAR KTM CUSTOMER 1
Congratulations on your decision to buy a KTM motorcycle. You are now the owner of a state-of-the-art sports motorcycle that will give you
enormous pleasure if you service and maintain it accordingly.
We wish you great pleasure riding the vehicle!
Enter the serial numbers of your vehicle below.

Chassis number ( p. 24) Dealer's stamp
Engine number ( p. 25)
Key number ( p. 25)
The owner's manual corresponded to the latest state of this series at the time of printing. Slight deviations resulting from continuing devel-
opment and design of our motorcycles cannot, however, be completely excluded.
All specifications are non-binding. KTM Sportmotorcycle AG specifically reserves the right to modify or delete technical specifications,
prices, colors, forms, materials, services, designs, equipment, etc., without prior notice and without specifying reasons, to adapt these
to local conditions, as well as to stop production of a particular model without prior notice. KTM accepts no liability for delivery options,
deviations from illustrations and descriptions, as well as misprints and other errors. The models portrayed partly contain special equipment
that does not belong to the regular scope of delivery.
DEAR KTM CUSTOMER 2
© 2008 by KTM-Sportmotorcycle AG, Mattighofen Austria

All rights reserved
Reproduction, even in part, is permitted only with the express written permission of the copyright owner.
ISO 9001(12 100 6061)

According to the international quality management standard ISO 9001, KTM uses quality assurance processes that lead to
the maximum possible quality of the products.
Issued by: TÜV Management Service
KTM-Sportmotorcycle AG
5230 Mattighofen, Austria
CONTENTS 3
MEANS OF REPRESENTATION ............................................... 7 Setting the clock .............................................................. 35

IMPORTANT NOTES ............................................................... 8 Combination instrument - display ODO ............................... 36
Overview of warning labels................................................. 12 Combination instrument - setting/resetting TRIP 1............... 36
VIEW OF VEHICLE................................................................ 20 Combination instrument - setting/resetting TRIP 2............... 37
View of vehicle, front left side............................................ 20 Combination instrument - TRIP F display............................ 38
View of vehicle, rear right .................................................. 22 Combination instrument - coolant temperature indicator ...... 38
LOCATION OF SERIAL NUMBERS ......................................... 24 Opening filler cap ............................................................. 39
Chassis number................................................................ 24 Closing filler cap .............................................................. 39
Type label........................................................................ 24 Handrails......................................................................... 40
Key number ..................................................................... 25 Seat release ..................................................................... 40
Engine number................................................................. 25 Passenger footrests........................................................... 41
Fork part number.............................................................. 26 Shift lever........................................................................ 41
Shock absorber part number.............................................. 26 Foot brake pedal .............................................................. 42
CONTROLS .......................................................................... 27 Side stand ....................................................................... 43
Clutch lever ..................................................................... 27 GENERAL TIPS AND HINTS ON PUTTING INTO
Hand brake lever .............................................................. 27 OPERATION......................................................................... 44
Light switch ..................................................................... 28 Advice on first use ............................................................ 44
Flasher switch .................................................................. 28 Running in the engine....................................................... 45
Horn button ..................................................................... 29 Loading the vehicle .......................................................... 46
Emergency OFF switch...................................................... 29 RIDING INSTRUCTIONS ....................................................... 48
Electric starter button ....................................................... 30 Checks before putting into operation .................................. 48
Ignition/steering lock ........................................................ 30 Starting ........................................................................... 49
Combination instrument .................................................... 31 Starting up ...................................................................... 50
Combination instrument - function buttons ......................... 31 Shifting, riding ................................................................. 51
Combination instrument - indicator lamps........................... 32 Braking ........................................................................... 54
Combination instrument - display....................................... 33 Stopping, parking ............................................................. 55
Combination instrument - speedometer............................... 34 Refueling......................................................................... 57
Setting kilometers or miles ................................................ 34
Combination instrument - time .......................................... 35
CONTENTS 4
SERVICE PLAN .................................................................... 59 Checking chain dirt .......................................................... 79

Important maintenance work to be carried out by an Cleaning the chain............................................................ 79
authorized KTM workshop. ................................................ 59 Checking the chain tension ............................................... 80
Important maintenance work to be carried out by an Adjusting the chain tension ............................................... 81
authorized KTM workshop. (as additional order)................... 61 Checking rear sprocket / engine sprocket for wear ................ 83
MAINTENANCE WORK ON CHASSIS AND ENGINE ................. 63 Checking chain wear ......................................................... 84
Jacking up the motorcycle ................................................. 63 Adjusting chain guide .................................................. 85
x
Removing the motorcycle from the work stand..................... 63 Checking the brake discs................................................... 85
Fork/shock absorber .......................................................... 64 Checking the free play of hand brake lever .......................... 86
Adjusting the compression damping of the fork ................... 64 Adjusting free travel of handbrake lever .............................. 87
Adjusting the rebound damping of the fork.......................... 65 Checking the front brake fluid level .................................... 88
Compression damping of the shock absorber ....................... 66
Adding front brake fluid x............................................... 88
Adjusting the low-speed compression damping of the shock
Checking the front brake linings......................................... 90
absorber .......................................................................... 66
Changing the front brake linings x ................................... 91
Adjusting the high-speed compression damping of the
shock absorber ................................................................. 68 Checking free play of foot brake lever ................................. 94
Adjusting the rebound damping of the shock absorber.......... 69 Adjusting basic position of footbrake lever x ..................... 95
Measuring the unloaded rear wheel sag............................... 70 Checking rear brake fluid level........................................... 96
Checking the static sag of the shock absorber ..................... 71 Adding rear brake fluid x................................................ 96
Checking the riding sag of the shock absorber ..................... 72 Checking the rear brake linings .......................................... 98
Adjusting the spring preload of the shock absorber x ......... 72 Changing the rear brake linings x ..................................... 98
Bleeding the fork legs ....................................................... 73 Removing the front wheel x ........................................... 101
Cleaning the dust boots of the fork legs .............................. 74 Installing the front wheel x ............................................ 103
Loosening the fork protection............................................. 75 Removing rear wheel .................................................. 104
x
Positioning the fork protection ........................................... 75 Installing the rear wheel x ............................................. 105
Checking the steering head bearing play x ........................ 76 Checking the rear hub rubber dampers x ........................ 106
Adjusting the play of the steering head bearing x .............. 77 Checking the tire condition.............................................. 107
Handlebar position ........................................................... 78 Checking the tire air pressure .......................................... 109
Adjusting handlebar position x ........................................ 78 Checking spoke tension................................................... 110
CONTENTS 5
Removing the seat .......................................................... 111 Changing the engine oil and filter, cleaning the oil
Mounting the seat .......................................................... 112 screens x..................................................................... 142
Removing the battery x................................................. 112 Draining the engine oil x ............................................... 143
Installing the battery ..................................................
x 113 Removing the oil filter x ................................................ 144
Recharging the battery x ............................................... 114 Installing the oil filter x ................................................ 146
Changing the main fuse .................................................. 116 Cleaning the oil screens x ............................................. 146
Changing the fuses of power consumers............................ 118 Filling up with engine oil x ............................................ 148
Adjusting the engine characteristic................................... 120 Adding engine oil ........................................................... 149
Headlight mask, removing with headlight.......................... 122 TROUBLESHOOTING.......................................................... 151
Installing the headlight mask with the headlight ................ 123 FLASHING CODE ............................................................... 154
Changing the headlight bulb............................................ 124 CLEANING......................................................................... 159
Changing the parking light bulb ....................................... 125 Cleaning motorcycle ....................................................... 159
Changing the flasher bulb ............................................... 126 CONSERVING FOR WINTER OPERATION ............................. 161
Check the headlamp setting ............................................ 127 Conservation for winter operation ..................................... 161
Adjusting the headlight range .......................................... 127 STORAGE .......................................................................... 162
Removing the air filter x ............................................... 128 Storage.......................................................................... 162
Installing the air filter x................................................ 129 Putting into operation after storage .................................. 163
Cooling system ............................................................... 130 TECHNICAL DATA - ENGINE ............................................... 164
Checking the antifreeze and coolant level ......................... 131 Capacity- engine oil ........................................................ 165
Checking the coolant level............................................... 133 Capacity - coolant........................................................... 165
Draining the coolant x.................................................. 135 TECHNICAL DATA - ENGINE TIGHTENING TORQUES........... 166
Filling the cooling system x........................................... 136 TECHNICAL DATA - CHASSIS ............................................. 169
Adjusting basic position of clutch lever............................. 138 Lighting equipment ........................................................ 170
Checking/rectifying the fluid level of the hydraulic clutch ... 138 Tires ............................................................................. 171
Checking the play in the gas Bowden cable ....................... 139 Capacity - fuel................................................................ 171
Adjusting the play in the gas Bowden cable x .................. 140 TECHNICAL DATA - FORK................................................... 172
Removing the engine guard ............................................. 141 TECHNICAL DATA - SHOCK ABSORBER .............................. 173
Installing the engine guard .............................................. 141 TECHNICAL DATA - CHASSIS TIGHTENING TORQUES ......... 175
Checking the engine oil level ........................................... 142 SUBSTANCES.................................................................... 178
CONTENTS 6
AUXILIARY SUBSTANCES................................................... 182

STANDARDS...................................................................... 184
INDEX ............................................................................... 185
MEANS OF REPRESENTATION 7
Symbols used
The meaning of specific symbols is described below.
Indicates an expected reaction (e.g. of a work step or a function).
Indicates an unexpected reaction (e.g. of a work step or a function).
All work marked with this symbol requires specialist knowledge and technical understanding. In the interest of your
own safety, have these jobs done in an authorized KTM workshop! There, your motorcycle will be serviced optimally
by specially trained experts using the specialist tools required.
Identifies a page reference (more information is provided on the specified page).
Formats used
The typographical and other formats used are explained in the following.
Specific name Identifies a proprietary name.
Name® Identifies a protected name.
Brand™ Identifies a trademark.

IMPORTANT NOTES 8
Use definition
KTM sport motorcycles are designed and constructed to meet the normal demands of regular road and light offroad operation (dirt roads),
but not for use on race courses.
Info
The motorcycle is authorized for public road traffic in the homologous version only.
Maintenance
A prerequisite for perfect operation and prevention of wear is that the engine and chassis maintenance and adjustment work described in
the owner's manual are properly carried out. Poor adjustment and tuning of the engine and chassis can lead to damage and breakage of
components.
Using the motorcycle in extreme conditions such as very muddy or wet roads can lead to above-average wear of components such as the
transmission train or the brakes. For this reason, it may be necessary to service or replace worn parts before the limit specified in the ser-
vice schedule is reached.
Pay careful attention to the prescribed running-in period, inspection and maintenance intervals. If you observe these exactly, you will
ensure a much longer service life for your motorcycle.
Warranty
The work prescribed in the service plan must only be carried out in an authorized KTM workshop and confirmed in the service record; oth-
erwise all warranty claims will be disregarded. No warranty claim can be met for damage resulting from manipulation and/or other changes
to the vehicle.
Fuel, oils, etc.

You should use the fuels, oils and greases according to specifications as listed in the owner's manual.
IMPORTANT NOTES 9
Spare parts, accessories

In the interests of your own safety, use only spare parts and accessories approved and/or recommended by KTM, and have these fitted in
an authorized KTM workshop. KTM accepts no liability for other products and any resulting damage.
The current KTM PowerParts for your vehicle can be found on the KTM website.
International KTM Website: http://www.ktm.com
Work rules
During assembly, non-reusable parts (e.g. self-locking screws and nuts, seals and seal rings, O-rings, pins, lock washers) must be replaced
by new parts.
If a thread lock (e.g. Loctite®) is used for screw connections, be sure to comply with the manufacturer's specific advice on its usage.
Parts that you want to reuse following repairs and servicing should be cleaned and checked for damage and wear. Change damaged or
worn parts.
Following repairs or servicing, the vehicle must be checked for roadworthiness.
Transport
Note
Danger of damage The parked vehicle can roll away or fall over.
– Always place the vehicle on a firm and even surface.
Note
Fire hazard Some vehicle components get very hot when the machine is driven.
– Do not place the vehicle where there are flammable or explosive substances. Do not place objects over the vehicle while it is still warm
from being run. Always let the vehicle cool first.
– Switch off the engine and remove the ignition key.

– Use straps or other suitable devices to secure the motorcycle against accidents or falling over.
IMPORTANT NOTES 10
Environment
Offroad motorcycling is a wonderful sport and we naturally hope that you will be able to enjoy it to the fullest. However, it is a potential
problem for the environment and can lead to conflicts with other persons. But if you use your motorcycle responsibly, you can ensure that
such problems and conflicts do not have to occur. To protect the future of motorcycle sport, make sure that you use your motorcycle
legally, display environmental consciousness, and respect the rights of others.
IMPORTANT NOTES 11
IMPORTANT NOTES 12
Overview of warning labels

2.1
800103-10
IMPORTANT NOTES 13
1 Type label, Canada

2 Type label, USA
3 Information, emission control
4 Information, noise emission
5 Information, suspension setting
6 Information, chain tension
7 Information, fuel evaporation system
8 Information, putting into operation
800110-01
Type label, Canada
IMPORTANT NOTES 14
100333-01
Type label, USA
800104-10
Information, emission control
IMPORTANT NOTES 15
800105-10
Information, noise emission
Information, suspension setting
100337-01
IMPORTANT NOTES 16
Information, chain tension
100338-01
Information, fuel evaporation system
100336-01
Information, putting into operation
700210-01
IMPORTANT NOTES 17
Notes/warnings
Pay close attention to the notes/warning.
Info
Various information and warning labels are affixed to the vehicle. Do not remove information/warning labels. If they are missing,
you or others may not recognize dangers and may therefore be injured.
Grades of risks
Danger
Identifies a danger that will immediately and invariably lead to fatal or serious permanent injury if the appropriate measures are not
taken.
Warning
Identifies a danger that is likely to lead to fatal or serious injury if the appropriate measures are not taken.
Caution
Identifies a danger that will possibly lead to light injury if the appropriate measures are not taken.
Note
Identifies a danger that will lead to considerable machine and material damage if the appropriate measures are not taken.
Warning
Identifies a danger that will lead to environmental damage if the appropriate measures are not taken.
IMPORTANT NOTES 18
Owner's manual
– It is important that you read this owner's manual carefully and completely before making your first trip. It contains useful information
and tips to help you operate and handle your motorcycle. Only then will you find out how to customize the motorcycle ideally for your
own use and how you can protect yourself from injury. The owner's manual also contains important information on servicing the motor-
cycle.
– The owner's manual is an important component of the motorcycle and should be handed over to the new owner if the vehicle is sold.
Reporting safety defects

If you believe that your vehicle has a defect which could cause an accident resulting in injury or death, you should immediately inform the
National Highway Traffic Safety Administration (NHTSA) in addition to notifying KTM North America, Inc.
If NHTSA receives similar complaints, it may open an investigation, and if it finds that a safety defect exists in a group of vehicles, it may
order a recall and remady campaign. However, NHTSA cannot become involved in individual problems between you, your dealer, or KTM
North America, Inc.
To contact NHTSA, you may either call the Auto Safety Hotline toll-free at 1–888–327–4236 or visit the website www.nhtsa.dot.gov, or
write to: NHTSA Headquarters, 1200 New Jersey Avenue, SE, West Building, Washington, DC 20590. You can also obtain other informa-
tion about motor vehicle safety from the Hotline.
Noise emission warranty

KTM Sportmotorcycle AG warrants that this exhaust system, at the time of sale, meets all applicable U.S. EPA Federal noise standards.
This warranty extends to the first person who buys this exhaust system for purposes other than resale, and to all subsequent buyers.
Warranty claims should be directed to:
KTM North America, Inc., Customer Support, 1119 Milan Ave., Amherst, OH 44001, USA
Phone: (440) 985–3553
www.ktmusa.com
KTM Canada, Inc., Customer Support, 1375-1 Marie-Victorin, Saint-Bruno, QC J3V 6B7
Phone: (450) 441–4451 x 4250
www.ktmcanada.com
IMPORTANT NOTES 19
Tampering warning
Tampering with noise control system prohibited.Federal law prohibits the following acts or causing thereof:
The removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement, of any device or
element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate pur-
chaser or while it is in use, or
the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person.
Among those acts presumed to constitute tampering are the acts listed below.
Removal of, or puncturing the muffler, baffles, header pipes or any other components which conducts exhaust gases.
Removal or puncturing of any part of the intake system.
Lack of proper maintenance.
Replacing any moving part of the vehicle, or parts of the exhaust or intake system, with parts other than those specified by the manu-
facturer.
Warning, operating noise

This product should be checked for repair or replacement if the motorcycle noise has increased significantly through use. Otherwise, the
owner may become subject to penalties under state and local ordinances.
Consumer rights
Warranty claims should be directed to an authorized KTM workshop. If you are not satisfied, please contact:
KTM North America, Inc., Customer Support, 1119 Milan Ave., Amherst, OH 44001, USA
Phone: (440) 985–3553
www.ktmusa.com
KTM Canada, Inc., Customer Support, 1375-1 Marie-Victorin, Saint-Bruno, QC J3V 6B7
Phone: (450) 441–4451 x 4250
www.ktmcanada.com
Your rights may vary depending on national and regional laws.
VIEW OF VEHICLE 20
View of vehicle, front left side

3.1
800106-10
VIEW OF VEHICLE 21
1 Hand brake lever

2 Clutch lever
3 Handrail
4 Filler cap
5 Seat
6 Front brake caliper
7 Shift lever
8 Engine number
9 Side stand
10 Footrest
11 Seat release strap
VIEW OF VEHICLE 22
View of vehicle, rear right

3.2
800107-10
VIEW OF VEHICLE 23
1 Ignition/steering lock
2 Rear mirror
3 Light switch, flasher switch, horn button
4 Combination instrument
5 Emergency OFF switch, electric starter button
6 Throttle grip
7 Chassis number
8 Brake caliper, rear
9 Passenger footrest
10 Shock absorber, rebound damping
11 Foot brake pedal
12 Level viewer, engine oil
LOCATION OF SERIAL NUMBERS 24
Chassis number
4.1
The chassis number  is stamped on the steering head on the right.
100217-10
Type label
4.2
Type label  is located on the upper right frame tube below the seat.
100218-10
Key number
4.3
The key number  can be found on the KEYCODECARD.
Info
You need the key number to order a spare key. Keep the KEYCODECARD in a safe
place.
100179-10
Engine number
4.4
The engine number  is stamped on the left side of the engine under the engine sprocket.
100211-10
Fork part number

4.5
The fork part number  is stamped on the inner side of the fork stub.
800072-10
Shock absorber part number

4.6
The shock absorber part number  is on the right of the shock absorber.
100216-10
CONTROLS 27
Clutch lever
5.1
The clutch lever  is fitted on the left side of the handlebar.

The clutch is hydraulically operated and self-adjusting.
100219-10
Hand brake lever

5.2
The hand break lever  is fitted on the right side of the handlebar.
The hand brake lever operates the front brake.
100220-10
CONTROLS 28
Light switch
5.3
The light switch  is fitted on the left side of the handlebar.

Possible states
Low beam on – Light switch is turned downwards. In this position, the low
beam and tail light are switched on.
High beam on – Light switch is turned upwards. In this position, the high
beam and the tail light are switched on.
100222-10
Flasher switch
5.4
The flasher switch  is fitted on the left side of the handlebar.

Possible states
Flasher light off
Flasher light, left, on – Flasher switch pressed to the right. The flasher
switch returns automatically to the central position after use.
Flasher light, right, on – Flasher switch pressed to the right. The flasher
switch returns automatically to the central position after use.
100223-10 To switch off the flasher light, press the flasher switch towards the switch case.
CONTROLS 29
Horn button
5.5
The horn button  is fitted on the left side of the handlebar.

Possible states
• Horn button in neutral position
• Horn button pressed – The horn is operated in this position.
100224-10
Emergency OFF switch

5.6
The emergency OFF switch  is fitted on the right side of the handlebar.
Possible states
Emergency OFF switch off – In this position, the ignition circuit is inter-
rupted, a running engine stops, and the engine cannot be started.
Emergency OFF switch on – This position is necessary for operation as the

ignition circuit is closed.
100225-10
CONTROLS 30
Electric starter button

5.7
The electric starter button  is fitted on the right side of the handlebar.
Possible states
• Electric starter button in basic position
• Electric starter button pressed – In this position, the electric starter is actuated.
100226-10
Ignition/steering lock
5.8
The ignition/steering lock  is located in front of the seat.

Possible states
Ignition OFF – In this position, the ignition circuit is interrupted, a running
engine stops, and a non-running engine will not start. The ignition key can
be removed.
Ignition ON – In this position, the ignition circuit is closed and the engine
can be started.
Steering locked – In this position, the ignition circuit is interrupted and the
600825-01 steering locked. The ignition key can be removed.
CONTROLS 31
Combination instrument
5.9
The combination instrument is installed in front of the handlebar.

The combination instrument is divided into 3 function areas.
 Function buttons
 Indicator lamps
 Display
800083-10
Combination instrument - function buttons

5.10
You can change the display mode with the M button .

Possible display modes are distance traveled (Odo), trip master 1 (Trip 1) and trip mas-
ter 2 (Trip 2).
Press the S button  to reset the trip master 1 function (Trip 1) and trip master 2 function
(Trip 2) to 0.00.
800083-11
CONTROLS 32
Combination instrument - indicator lamps

5.11
The indicator lamps offer additional information about the operating state of the motorcy-
cle.
Possible states
The flasher indicator lamp flashes green simultaneously with the flashers
– Flasher light is switched on.
Fuel level warning lamp lights up orange – Fuel level has reached the
reserve mark. Display switched to Trip F.
Temperature warning lamp lights up red – Coolant has reached a critical

800083-12
value.
High beam indicator lamp lights up blue – High beam is switched on.
The idle speed indicator lamp lights up green – The transmission is

switched to idle.
FI warning lamp (MIL) lights/flashes orange – The OBD has detected an

emission- or safety-critical fault.
CONTROLS 33
Combination instrument - display

5.12
When you switch on the ignition, all display segments light up for a second as a function
test.
800083-13
LEnGth
Following the display function test, the wheel circumference LEnGth is shown for one sec-
ond.
Info
2205 mm equals the circumference of the 21" front wheel with a series production
tire.
The display then changes to the last selected mode.

800083-14
CONTROLS 34
Combination instrument - speedometer

5.13
The speed  is shown in kilometers per hour km/h or in miles per hour mph.
800083-16
Setting kilometers or miles

5.14
Info
If you change the unit, the value is retained and converted accordingly.
Making the setting according to the country.
Condition
The motorcycle is standing.
CONTROLS 35
– Switch on the ignition by turning the ignition key to position ON .

– Press the M button repeatedly until the Odo mode is active.
– Keep the M button pressed until the display mode changes from km/h to mph or from
mph to km/h.
Guideline
Activation duration of M button 10 s
800083-15
Combination instrument - time

5.15
The time is shown in area  of the display.
Info
The time must be reset after the battery is reconnected or when the fuse is changed.
800083-17
Setting the clock

5.16
Condition
The motorcycle is standing.
CONTROLS 36

– Press the M button repeatedly until the Odo mode is active.
– Keep the M button and the S button pressed simultaneously.
The time display begins to flash.
– Press the M button to set the hour.
– Press the S button to set the minute.
– Keep the M button and the S button pressed simultaneously.
800083-18
The time is set.
Combination instrument - display ODO

5.17
In the Odo display mode, the total distance traveled is shown in kilometers or miles.
Info
This value is retained, even if the battery is disconnected and/or the fuse blows.
800083-18
Combination instrument - setting/resetting TRIP 1

5.18
Info
The TRIP 1 trip counter is always running and counts up to 999.9.
The trip counter can be used to measure the distance covered during trips or between two refueling stops. After the value 999.9 is
reached, the trip counter starts at 0.0 again.
CONTROLS 37

– Press the M button repeatedly until the Trip 1 mode is active.
– Keep the S button pressed.
The Trip 1 display is set to 0.00.
800083-19
Combination instrument - setting/resetting TRIP 2

5.19
Info
The TRIP 2 trip counter is always running and counts up to 999.9.
The trip counter can be used to measure the distance covered during trips or between two refueling stops. After the value 999.9 is
reached, the trip counter starts at 0.0 again.

– Press the M button repeatedly until the Trip 2 mode is active.
– Keep the S button pressed.
The Trip 2 display is set to 0.00.
800083-20
CONTROLS 38
Combination instrument - TRIP F display

5.20
If the fuel level drops to the reserve mark, the display automatically changes to Trip F and
starts to count from 0.0, regardless of the previous display mode.
Info
Parallel to the Trip F display, the fuel warning light switches on.
800083-21
Combination instrument - coolant temperature indicator

5.21
The temperature display consists of 8 bars. The more bars that light up, the hotter the
coolant. When the upper bar lights up, all bars in the display begin to flash and the tem-
perature warning lamp lights up.
Possible states
• Engine cold – No bars light up.
• Engine warm – Four bars light up.
• Engine hot – All eight bars flash.
800085-10
CONTROLS 39
Opening filler cap

5.22
– Lift the cover of the filler cap  and insert the ignition key.
– Turn the ignition key 90° counterclockwise and remove the filler cap.
Info
The filler cap has a tank air vent system.
100227-10
Closing filler cap

5.23
– Put the filler cap back on and turn the ignition key 90° clockwise.
– Remove the ignition key and fold down the cover.
100228-01
CONTROLS 40
Handrails
5.24
The handrails  are used for moving the motorcycle around.

When you have a passenger, the passenger can hold on the handrails during the journey.
100229-10
Seat release
5.25
The seat can be released using strap .
100230-10
CONTROLS 41
Passenger footrests
5.26
The passenger footrests can be folded up and down.

Possible states
• Passenger footrests folded up – For operation without a passenger.
• Passenger footrests folded down – For operation with a passenger.
100231-01
Shift lever
5.27
The shift lever  is mounted on the left side of the engine.
100215-10
CONTROLS 42
The gear positions can be seen in the photograph.

The neutral or idle position is between the first and second gears.
100212-10
Foot brake pedal

5.28
The footbrake pedal  is located in front of the right footrest.

The footbrake pedal operates the rear brake.
100232-10
CONTROLS 43
Side stand
5.29
The side stand  is coupled with the safety electric starter system - see the riding instruc-
tions.
Possible states
• Side stand folded out – The vehicle can be supported on the side stand. The safety
electric starter system is active.
• Side stand folded in – This position is mandatory for all journeys. The safety electric
starter system is inactive.
100233-10
GENERAL TIPS AND HINTS ON PUTTING INTO OPERATION 44
Advice on first use

6.1
Danger
Danger of accidents Danger from insufficient traffic competence.
– Do not use the vehicle if you are not fit to deal with traffic or if you have consumed alcohol and/or medicaments or drugs.
Warning
Risk of injury Missing or insufficient protective clothing increases the risk of injury.
– Wear protective clothing (helmet, boots, gloves, pants and jacket with protectors) every time you ride the vehicle. Always wear
protective clothing, which must be in perfect condition and meet legal requirements.
Warning
Danger of crashing Impairment of riding behavior due to different tire tread patterns on front and rear wheels.
– The front and rear wheels must be fitted with tires with similar tread patterns to prevent loss of control over the vehicle.
Warning
Danger of accidents Uncontrollable handling characteristics due to non-approved and/or non-recommended tires/wheels.
– Only tires/wheels approved by KTM and with the corresponding speed index should be used.
Warning
Danger of accidents Reduced road grip with new tires.
– New tires have a smooth roll surface and therefore cannot provide full road grip. The entire roll surface must be roughened in
the first 200 kilometers (124.3 miles) by moderate driving at alternating angles. The full grip is not reached until the vehicle
has been run in.
Warning
Danger of accidents Brake system failure.
– If the foot brake pedal is not released, the brake linings drag permanently. The rear brake can fail due to overheating. Take your
foot off the foot brake pedal if you do not want to brake.
Info
When using your vehicle, remember that others may feel disturbed by excessive noise.
– Make sure that the pre-delivery inspection work has been carried out by an authorized KTM workshop.
You receive a delivery certificate and the service record at vehicle handover.
– Before your first trip, read the entire operating instructions carefully.
– Get to know the controls.
– Adjust the basic position of clutch lever. ( p. 138)
– Adjust the free travel of the handbrake lever. ( p. 87)
– Adjust the basic position of the footbrake lever. x( p. 95)
– Get used to handling the motorcycle on a suitable piece of land before making a longer trip. Try also to ride as slowly as possible and
in a standing position to get a better feeling for the vehicle.
– Do not make any offroad trips that over-stress your ability and experience.
– Hold the handlebar firmly with both hands and keep your feet on the footrests when riding.
– Run the engine in.
Running in the engine

6.2
– During the running-in phase, do not exceed the specified engine speed and engine performance.
Guideline
Maximum engine speed
During the first: 1,000 km (621.4 mi) 6,000 rpm
After the first: 1,000 km (621.4 mi) 7,800 rpm
– Avoid fully opening the throttle!
Loading the vehicle

6.3
Warning
Danger of accidents Unstable riding behavior.
– Do not exceed the maximum permitted weight and axle loads. The overall weight consists of: motorcycle operational and with a
full tank, driver and passenger with protective clothing and helmet, baggage.
Warning
Danger of accidents Unstable handling characteristics due to incorrect mounting of suitcase and/or tank rucksack.
– Mount and secure suitcase and tank rucksack according to the manufacturer's instructions.
Warning
Danger of accidents Unstable handling characteristics at high speed.
– Adapt your speed according to your payload. Ride more slowly if your motorcycle is loaded with cases or other baggage.
Maximum speed with baggage 130 km/h (80.8 mph)
Warning
Danger of accidents Risk of breakage of suitcase system.
– If you have fitted suitcases on your motorcycle, read the manufacturer's specifications concerning the maximum payload.
Warning
Danger of accidents Poor visibility for other road users due to slipped baggage.
– If the tail light is covered, you are less visible to traffic behind you, especially in the dark. Check that your baggage is fixed
properly at regular intervals.
Warning
Danger of accidents Changed handling characteristics and longer stopping distance with excessive payload.
– Adapt your speed according to your payload.
Warning
Danger of accidents Unstable handling characteristics due to slipped baggage.
– Check the way your baggage is fixed regularly.
Warning
Danger of burns A hot exhaust system can burn baggage.
– Fasten your baggage in such a way that it cannot be burned or singed by the hot exhaust system.
– If you carry any baggage, make sure it is fixed firmly as close as possible to the center of the vehicle and ensure even weight distribu-
tion between the front and rear wheels.
– Do not exceed the overall maximum permitted weight and the axle loads.
Guideline
Maximum permissible overall weight 350 kg (772 lb.)
Maximum permissible front axle load 150 kg (331 lb.)
Maximum permissible rear axle load 200 kg (441 lb.)
RIDING INSTRUCTIONS 48
Checks before putting into operation

7.1
Info
Make sure that the motorcycle is in a perfect technical condition before use.
In the interests of riding safety, make a habit of making a general check before you ride.
– Check the engine oil level. ( p. 142)

– Check the engine for loss of oil.
– Check the fuel level.
– Bleed the fork legs. ( p. 73)
Guideline
All 1,000 km (621.4 mi)
– Check the chain tension. ( p. 80)
– Clean the chain. ( p. 79)
– Check the tire condition. ( p. 107)
– Check the tire air pressure. ( p. 109)
– Check the front brake fluid level. ( p. 88)
– Check the rear brake fluid level. ( p. 96)
– Check the front brake linings. ( p. 90)
– Check the rear brake linings. ( p. 98)
– Check brake system function.
– Check the coolant level. ( p. 133)
– Check that all operating elements are correctly adjusted and free to move.
– Check the functioning of the electrical equipment.
– Check that baggage is correctly secured.
– Sit on the motorcycle and check the rear mirror setting.
Starting
7.2
Danger
Danger of poisoning Exhaust gases are poisonous and can result in unconsciousness and/or death.
– When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in a closed space
without an effective exhaust extraction system.
Caution
Danger of accidents If the vehicle is operated with a discharged battery or without a battery, electronic components and safety
equipment may be damaged.
– Never operate the vehicle with a discharged battery or without a battery.
Note
Engine failure High engine speeds in cold engines have a negative effect on the service life of the engine.
– Always warm up the engine at low engine speeds.
– Turn the emergency OFF switch to the position .

After you switch on the ignition, you can hear the fuel pump working for about 2
seconds. At the same time, the function test of the combination instrument is run.
– Shift gear to neutral.
The green idling speed indicator lamp N  lights up.
– Press the electric starter button .
Info
Do not press the electric starter button until the function test of the combination
instrument is finished.
When starting, DO NOT open the throttle. If you open the throttle during the start-
ing procedure, fuel is not injected by the engine management system and the
engine cannot start.
Press the starter for a maximum of 5 seconds. Wait for a least 5 seconds before
trying again.
This motorcycle is equipped with a safety start system. You can only start the
engine if the gearbox is in neutral or if the clutch is pulled when a gear is
engaged. If the sidestand is folded out and you shift into gear and release the
800088-10
clutch, the engine stops.
– Take the weight off the side stand and swing it back up with your foot as far as it will
go.
Starting up
7.3
– Pull the clutch lever, engage 1st gear, release the clutch lever slowly and simultaneously open the throttle carefully.
Shifting, riding
7.4
Warning
Danger of accidents An abrupt load alterations can cause the vehicle to get out of control.
– Avoid abrupt load alterations and sudden braking actions, and adapt your speed to the road conditions.
Warning
Danger of accidents If you change down at high engine speed, the rear wheel can lock up.
– Do not change into a low gear at high engine speed. The engine races and the rear wheel can block.
Warning
Danger of accidents Malfunctions caused by incorrect ignition key position.
– Do not change the ignition key position during a journey.
Warning
Danger of accidents Distraction from traffic activity by adjustments to the vehicle.
– Make all adjustments when the vehicle is at a standstill.
Warning
Risk of injury The passenger must be capable of sitting correctly on the passenger seat.
– The passenger must hold on to the rider or the handrails and place his feet on the passenger footrests. Note the regulations
governing the minimum age of passengers in your country.
Warning
Danger of accidents Danger of accidents caused by dangerous driving.
– Observe the traffic regulations and ride defensively and with foresight in order to recognize danger as early as possible.
Warning
Danger of accidents Reduced road grip with cold tires.
– On every journey, take the first miles carefully at moderate speed until the tires reach operating temperature and optimal road
grip is ensured.
Warning
has been run in.
Warning
Danger of accidents Unstable riding behavior.
– Do not exceed the maximum permitted weight and axle loads. The overall weight consists of: motorcycle operational and with a
full tank, driver and passenger with protective clothing and helmet, baggage.
Warning
Danger of accidents Unstable handling characteristics due to slipped baggage.
– Check the way your baggage is fixed regularly.
Warning
Danger of accidents After a fall, check the vehicle.
– After a fall, check the vehicle as usual before putting it into operation.
Note
Engine failure Unfiltered intake air has a negative effect on the service life of the engine.
– Never ride the vehicle without an air filter since dust and dirt can get into the engine and result in increased wear.
Note
Engine failure Overheating of engine.
– If the coolant temperature warning lamp lights up, stop and switch off the engine. Allow the engine to cool down and check the
coolant level in the radiator, and top up if necessary. If you continue with the coolant temperature warning lamp alight, you may have
engine failure.
Info
If you hear unusual noises while riding, stop immediately, switch off the engine and contact an authorized KTM workshop.
– When conditions allow (incline, road situation, etc.), you can shift into a higher gear.
– Release the throttle while simultaneously pulling the clutch lever, shift into the next
gear, release the clutch and open the throttle.
Info
You can see the positions of the 6 forward gears in the figure. The neutral or idle
position is between the first and second gears. First gear is used for starting off
or for steep inclines.
The operating temperature is reached when 4 bars of the temperature indicator
100212-10 light up.
– After reaching maximum speed by fully opening the throttle grip, turn the throttle back
so it is ¾ open. This will barely reduce the speed but fuel consumption will be consid-
erably lower.
– Accelerate only up to a speed suitable for the road surface and weather conditions.
When traveling in bends, do not shift, and accelerate very carefully.
– To shift down, brake if necessary and close the throttle at the same time.
– Pull the clutch lever and shift into a lower gear, release the clutch lever slowly and open
the throttle or shift again.
– If the engine stalls (e.g. at a crossroads), just pull the clutch lever and press the starter
button. You do not have to shift into neutral.
– Switch off the engine if you expect to be standing for a long time.
– Avoid frequent and longer slipping of the clutch. This heats the engine oil, the engine
and the cooling system.
– Ride with a lower engine speed instead of with a high engine speed and a slipping
clutch.
– If the FI warning lamp (MIL) lights up during a trip, stop immediately. When you shift to
neutral, the FI warning lamp (MIL) starts to flash.
Info
From the flashing rhythm, you can derive a two-digit number, the so-called
flashing code. The flashing code tells you which component has a fault.
Braking
7.5
Warning
Danger of accidents If you brake too hard, the wheels can lock.
– Adapt your braking to the traffic situation and the road conditions.
Warning
Danger of accidents Reduced braking due to wet or dirty brakes.
– Clean or dry dirty or wet brakes by riding and braking gently.
Warning
Danger of accidents Reduced braking caused by spongy pressure point of front or rear brake.
– Have the brake system checked in an authorized KTM workshop, and do not ride any further.
Warning
– If the foot brake pedal is not released, the brake linings drag permanently. The rear brake can fail due to overheating. Take your
foot off the foot brake pedal if you do not want to brake.
Warning
Danger of accidents Longer stopping distance due to higher overall weight.
– Take the longer stopping distance into account when carrying a passenger and baggage.
Warning
Danger of accidents Delayed brake action on salted roads.
– Salt can be deposited on the brake discs. To achieve the normal braking effect, the brake discs must first be cleaned by brak-
ing.
– To brake, release the throttle and operate the front and rear brakes simultaneously.
– On sandy, wet or slippery surfaces, use the rear brake.
– Braking should always be completed before you go into a bend. Change down to a lower gear appropriate to your road speed.
– On long downhill stretches, use the braking effect of the engine. Change down one or two gears, but do not overstress the engine. In
this way, you have to brake far less and the brakes do not overheat.
Stopping, parking
7.6
Warning
Risk of misappropriation Usage by unauthorized persons.
– Never leave the vehicle while the engine is running. Secure the vehicle against use by unauthorized persons. If you leave the
vehicle, lock the steering and remove the ignition key.
Warning
Danger of burns Some vehicle components get very hot when the machine is driven.
– Do not touch hot components such as exhaust system, radiator, engine, shock absorber and brakes. Allow these components to
cool down before starting work on them.
Note
Note
Fire hazard Some vehicle components get very hot when the machine is driven.
– Do not place the vehicle where there are flammable or explosive substances. Do not place objects over the vehicle while it is still warm
from being run. Always let the vehicle cool first.
Note
Material damage Damage and destruction of components by excessive load.
– The side stand is designed for the weight of the motorcycle only. Do not sit on the motorcycle when it is supported by the side stand
only. The side stand and/or the frame could be damaged and the motorcycle could fall over.
– Brake the motorcycle.

– Switch off the ignition by turning the ignition key to position OFF .
Info
If the engine is switched off with the emergency OFF switch and the ignition remains switched on at the ignition lock, power
continues to flow to most power consumers and the battery will discharge. You should therefore always switch off the engine
with the ignition key - the emergency OFF switch is intended for emergencies only.
– Park the motorcycle on a hard surface.

– Swing the side stand forward with your foot as far as it will go and lean the vehicle on it.
– Lock the steering by turning the handlebar fully to the left, pressing down the ignition key to position and turning it to position .
To make the steering lock engage more easily, move the handlebar a little to the left and right. Remove the ignition key.
Refueling
7.7
Danger
Fire hazard Fuel can easily catch fire.
– Never fill up the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no fuel is
spilt, especially on hot vehicle components. Clean up spilt fuel immediately.
– Fuel in the fuel tank expands when warm and can escape if the tank is overfilled. See specifications on filling up with fuel.
Warning
Danger of poisoning Fuel is poisonous and a health hazard.
– Avoid contact between fuel and skin, eyes and clothing. Do not inhale fuel vapors. If fuel gets into your eyes, rinse immediately
with water and contact a doctor. Wash affected skin areas immediately with soap and water. If fuel is swallowed, contact a doc-
tor immediately. Change clothing that has come into contact with fuel.
Warning
Environmental hazard Improper handling of fuel is a danger to the environment.
– Do not allow fuel to get into the ground water, the ground, or the sewage system.
Info
This motorcycle is equipped with a regulated catalyst. Leaded fuel will destroy the catalyst. You should therefore use unleaded fuel
only.
– Switch off engine.

– Open the filler cap. ( p. 39)
– Fill the fuel tank with fuel up to measurement .
Guideline
Measurement of  20 mm (0.79 in)
Total fuel tank 12 l (3.2 US gal) Super unleaded (ROZ 95 / RON 95 /

capacity, approx. PON 91) ( p. 181)
400405-10 – Close the filler cap. ( p. 39)
– Press the S button  for two seconds.
The fuel level warning lamp  switches off. Trip F is set to 0.0 and appears in the
previous display mode.
Info
If you do not press the S button , the reset takes place automatically after
about three minutes.
800083-25
SERVICE PLAN 59
Important maintenance work to be carried out by an authorized KTM workshop.

8.1
K10N K50A K100A J1A J2A

Engine Change the engine oil and filter, clean the oil screens. x( p. 142) • • • • •
Check and adjust valve clearance. x • •
Check engine mounting screws for tightness. • • • • •
Replace spark plug. •
Check engine bolts accessible from outside for tightness. • • • • •
Fuel injection Check connection boots for cracks and leakage. x • • •
Read out the error memory with a KTM diagnostic tool. x • • • • •
Check fuel hoses, SLS hoses and vent hoses for damage, correct fit-
• • • • •
ting and leaks. x
Clean, check and grease the O-ring of the fuel hose connection. x • • • •
Check the cable harness of the throttle valve body for damage and cor-
• • •
rect positioning.x
Attachments Check the cooling system for leakage. • • • • •
Check the antifreeze and coolant level. ( p. 131) • • • • •
Check the functioning of the radiator fan. x • • • • •
Check the exhaust system for leaks and correct fitting and check that
• • • • •
the exhaust holders are tight. x
Check Bowden cables for damage, smooth operation, routing without
• • • • •
sharp bends and setting.
Check/rectify the fluid level of the hydraulic clutch. ( p. 138) • • • •
Check air filter and change if necessary. Clean the air filter box. x • • • •
Check fuel tank for tightness. • • • • •
Check cables for damage and routing without sharp bends. x • • • • •
SERVICE PLAN 60

Attachments Check the headlamp setting. ( p. 127) • • • • •
Check the functioning of the electrical equipment. • • • • •
Check screws and nuts for tightness. • • • • •
Brakes Check the front brake linings. ( p. 90) • • • • •
Check the rear brake linings. ( p. 98) • • • • •
Check the brake discs. ( p. 85) • • • • •
Check the front brake fluid level. ( p. 88) • • • • •
Check the rear brake fluid level. ( p. 96) • • • • •
Change brake fluid. x •
Check brake lines for damage and leakage. • • • • •
Check the free play of the foot brake lever. ( p. 94) • • • • •
Check braking. • • • • •
Check screws and guide bolts of brake system for tightness.x • • • • •
Chassis Check shock absorber and fork for leakage and functioning. x • • • • •
Clean the dust boots of the fork legs. ( p. 74) • • • •
Bleed the fork legs. ( p. 73) • • • • •
Check swingarm bearing. x • • • • •
Check the steering head bearing play. x( p. 76) • • • • •
Check all screws to see if they are tight. • • • • •
Grease Pro‑Lever deflector. x •
Wheels Check the spoke tension. ( p. 110) • • • • •
Check rim run-out. x • • • • •
Check the tire condition. ( p. 107) • • • • •
SERVICE PLAN 61

Wheels Check the tire air pressure. ( p. 109) • • • • •
Check the chain wear. ( p. 84) • • • • •
Check rear sprocket / engine sprocket for tightness. • • • • •
Check rear sprocket / engine sprocket for wear. ( p. 83) • • • • •
Check the chain tension. ( p. 80) • • • • •
Clean the chain. ( p. 79) • • • • •
Check wheel bearing for play. x • • • •
Check the rear hub rubber dampers. x( p. 106) • • • •
K10N: after 1,000 km (621.4 mi)
K50A: every 5,000 km (3,107 mi) / after every race
K100A: every 10,000 km (6,214 mi)
J1A: annually
J2A: every 2 years
Important maintenance work to be carried out by an authorized KTM workshop. (as additional order)
8.2
K100A J1A J2A

Carry out a complete fork service. x • •
Carry out a complete shock absorber service. x • •
Clean and grease steering head bearing and sealing elements. x •
Treat electric contacts with contact spray. • •
Clean the battery terminals and treat them with contact grease. • •
Change coolant. x •
Change the fuel evaporation container. x • •
K100A: every 10,000 km (6,214 mi)
SERVICE PLAN 62
J1A: annually
J2A: every 2 years
MAINTENANCE WORK ON CHASSIS AND ENGINE 63
Jacking up the motorcycle

9.1
Note
– Jack up the motorcycle on the underride guard underneath the engine. The wheels must
no longer touch the ground.
– Secure the motorcycle against falling over.
800089-10
Removing the motorcycle from the work stand

9.2
Note
– Remove the motorcycle from the work stand and rest it on its side stand.
– Remove the work stand.
Fork/shock absorber
9.3
The fork and the shock absorber offer many options of adapting the chassis to your riding
style and the payload.
Info
To help you adapt the vehicle, we have summarized our findings in Table . You
can find the table on the underside of the seat.
These adjustments should be understood as a guideline and should always be the basis
of your own personal chassis adaptation. Do not change the adjustments at random or by
100242-01
more than ± 40%, since otherwise the riding characteristics could deteriorate, particularly
at high speeds.
Adjusting the compression damping of the fork

9.4
Info
The hydraulic compression damping determines the fork suspension behavior.
– Remove protection covers .

– Turn adjusting screws  clockwise until they stop.
Info
The adjusting screws are located at the bottom end of the fork legs.
Make the same adjustment on both fork legs.
800074-10
– Turn back counterclockwise by the number of clicks corresponding to the fork type.
Guideline
Compression damping
Comfort 20 clicks
Standard 15 clicks
Sport 10 clicks
Full payload 10 clicks
Info
Turn clockwise to increase damping, turn counterclockwise to reduce suspension
damping.
– Mount protection covers .
Adjusting the rebound damping of the fork

9.5
Info
The hydraulic rebound damping determines the fork rebound behavior.
– Turn adjusting screws  clockwise until they stop.
Info
The adjusting screws are located at the top end of the fork legs.
Make the same adjustment on both fork legs.
800090-10
– Turn back counterclockwise by the number of clicks corresponding to the fork type.
Guideline
Rebound damping
Comfort 20 clicks
Standard 15 clicks
Sport 10 clicks
Info
damping.
Compression damping of the shock absorber

9.6
The shock absorber can regulate compression damping in low- and high-speed range separately (Dual Compression Control).
The term low speed and high speed refer to the movement of the shock absorber during compression and not the riding speed of the
motorcycle.
Changes in the settings in the low-speed range have an impact on the high-speed range and vice versa.
Adjusting the low-speed compression damping of the shock absorber

9.7
Danger
Danger of accidents The shock absorber is under high pressure.
– The shock absorber is filled with highly compressed nitrogen, so never dismantle the shock absorber or carry out any mainte-
nance on it yourself.
Info
The low-speed setting can be seen during the slow to normal compression of the shock absorber.
– Turn adjusting screw  clockwise with a screwdriver as far as the last perceptible click.
Info
Do not loosen nut !
– Turn back counterclockwise by the number of clicks corresponding to the shock

absorber type.
Guideline
Compression damping, low-speed
Comfort 20 clicks
Standard 15 clicks
Sport 10 clicks
Info
damping.
100245-10
Adjusting the high-speed compression damping of the shock absorber

9.8
Danger
Info
The high-speed setting can be seen during the fast compression of the shock absorber.
– Turn adjusting screw  clockwise as far as it will go using an open end wrench.
Info
Do not loosen nut !
– Turn back counterclockwise by the number of turns corresponding to the shock

absorber type.
Guideline
Compression damping, high-speed
Comfort 2 turns
Standard 1.5 turns
Sport 1 turn
Full payload 1 turn
Info
damping.
100246-10
Adjusting the rebound damping of the shock absorber

9.9
Danger
– Turn adjusting screw  clockwise to the last perceptible click.

– Turn back counterclockwise by the number of clicks corresponding to the shock
absorber type.
Guideline
Rebound damping
Comfort 20 clicks
Standard 15 clicks
Sport 10 clicks
100247-10
Info
Turn clockwise to increase damping; turn counterclockwise to reduce suspension
damping.
Measuring the unloaded rear wheel sag

9.10
– Jack up the motorcycle. ( p. 63)

– Measure the distance – as vertical as possible – between the rear axle and a fixed point,
for example, a mark on the side cover.
– Make a note of the value as measurement .
A
0 – Remove the motorcycle from the work stand. ( p. 63)
400220-10
Checking the static sag of the shock absorber

9.11
– Measure distance  of rear wheel unloaded. ( p. 70)

– Ask someone to help you by holding the motorcycle upright.
– Measure the distance between the rear axle and the fixed point again.
A
0 – Make a note of the value as measurement .
Info
The static sag is the difference between measurements  and .
– Check the static sag.

Static sag 25 mm (0.98 in)
» If the static sag is less or more than the specified value:
– Adjust the spring preload of the shock absorber. x( p. 72)
B
0
400221-10
Checking the riding sag of the shock absorber

9.12
– Measure distance  of rear wheel unloaded. ( p. 70)

– With another person holding the motorcycle, the rider sits on the saddle with full
protective clothing in a normal sitting position (feet on footrests) and bounces up and
down a few times until the rear suspension levels out.
0
A – The other person now has to measure the distance between the rear axle and a fixed
point.
– Make a note of the value as measurement .
Info
The riding sag is the difference between measurements  and .
– Check the riding sag.

Riding sag 70… 80 mm (2.76… 3.15 in)
» If the riding sag differs from the specified measurement:
C – Adjust the riding sag. x
400222-10
Adjusting the spring preload of the shock absorber

9.13 x
Danger
Info
Before changing the spring preload, make a note of the present setting, e.g., by measuring the length of the spring.
– Remove the shock absorber. x

– After removing the shock absorber, clean it thoroughly.
– Loosen locking ring .
– Turn adjusting ring  until the spring is no longer under tension.
Hook wrench (T106S)
– Measure the overall spring length when not under tension.
– Tension the spring by turning the adjusting ring  to the prescribed value.
Guideline
Spring preload 20 mm (0.79 in)
700541-01 – Tighten locking ring .
– Install the shock absorber. x
Bleeding the fork legs
9.14
– Lean the motorcycle on the side stand.

– Remove bleeder screws  briefly.

Any excess pressure escapes from the interior of the fork.
– Mount and tighten bleeder screws.
Info
Carry out this action on both fork legs.
800091-10
Cleaning the dust boots of the fork legs

9.15

– Loosen the fork protection. ( p. 75)
– Push dust boot  of both fork legs downwards.
Info
The dust boots should remove dust and coarse dirt particles from the fork tubes.
Over time, dirt can penetrate behind the dust boots. If this dirt is not removed,
the oil seals behind can start to leak.
Warning
Danger of accidents Reduced braking due to oil or grease on the brake discs.
100293-10
– Always keep the brake discs free of oil and grease, and clean them with
brake cleaner when necessary.
– Clean and oil the dust boots and inner fork tube of both fork legs.
Universal oil spray ( p. 183)
– Press the dust boots back into their normal position.
– Remove excess oil.

– Position the fork protection. ( p. 75)
– Remove the motorcycle from the work stand. ( p. 63)
Loosening the fork protection

9.16
– Remove screws  and take off clamp.

– Remove screws  on left fork leg. Push the fork protection downwards.
– Remove the screws on the right fork leg. Push the fork protection downwards.
800092-10
Positioning the fork protection

9.17
– Position the fork protection on the left fork leg. Mount and tighten screws .
Guideline
Remaining screws, chassis M6 10 Nm (7.4 lbf ft)
– Position the brake line and cable harness. Put the clamp on, mount and tighten
screws .
– Position the fork protection on the right fork leg. Mount and tighten the screws.
Guideline
800092-11
Checking the steering head bearing play

9.18 x
Warning
Danger of accidents Unsafe riding behavior due to incorrect steering head bearing play.
– The steering head bearing play should be adjusted immediately in an authorized KTM workshop.
Info
If the bike is driven for a longer time with play in the steering head bearing, the bearing and the bearing seats in the frame can be
damaged after time.

– Move the handlebar to the straight-ahead position. Move the fork legs to and fro in the
direction of travel.
No play should be noticeable in the steering head bearing.
» If there is noticeable play present:
– Adjust the play of the steering head bearing. x( p. 77)
– Move the handlebar to and fro over the entire steering range.
The handlebar must be able to move easily over the entire steering range. No resting
100298-10 locations should be noticeable.
» If click positions are noticeable:
– Adjust the play of the steering head bearing. x( p. 77)
– Check the steering head bearing and change if necessary.
Adjusting the play of the steering head bearing

9.19 x
– Loosen screw . Remove screw .
– Loosen and retighten screw .
Guideline
Screw, top steering head M20x1.5 10 Nm (7.4 lbf ft)
– Using a plastic hammer, tap lightly on the upper triple clamp to avoid strains.
– Fully tighten screws .
Guideline
800093-10 Screw, top triple clamp M8 17 Nm
(12.5 lbf ft)
– Mount and tighten screw .
Guideline
Screw, steering stem M8 20 Nm Loctite® 243™
(14.8 lbf ft)
– Check the steering head bearing play. x( p. 76)
Handlebar position
9.20
On the upper triple clamp, there are 2 holes at a distance  to each other.
Distance  between holes 15 mm (0.59 in)
The holes on the handlebar support are placed at a distance  from the center.
0
A B
0
Distance  between holes 3.5 mm (0.138 in)
The handlebar can be mounted in 4 different positions. In this way, the handlebar can be
installed in the position most comfortable for the rider.
400271-11
Adjusting handlebar position

9.21 x
– Remove the four screws . Remove the handlebar clamp. Remove the handlebar and
1
0 lay it to one side.
2
0 Info
Protect the motorcycle and its attachments from damage by covering them.
Do not bend the cables and lines.
– Remove the two screws . Remove the handlebar support.

– Place the handlebar support in the required position. Fit and tighten the two screws .
400271-10 Guideline
Screw, handlebar support M10 40 Nm
(29.5 lbf ft)
Info
Position the left and right handlebar supports evenly.
– Position the handlebar.
Info
Make sure cables and wiring are positioned correctly.
– Position the handlebar clamp. Fit and evenly tighten the four screws .
Guideline
Screw, handlebar clamp M8 20 Nm Loctite® 243™
(14.8 lbf ft)
Checking chain dirt

9.22
– Check the chain for coarse dirt accumulation.

» If the chain is very dirty:
Cleaning the chain

9.23
Warning
Danger of accidents Oil or grease on the tires reduces their grip.
– Remove oil and grease with a suitable cleaning material.
Warning
– Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary.
Warning
Environmental hazard Hazardous substances cause environmental damage.
– Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations.
Info
The service life of the chain depends largely on its maintenance.
– Clean the chain regularly.

– Rinse off loose dirt with a soft jet of water.
– Remove old grease remains with chain cleaner.
Chain cleaner ( p. 182)
– After drying, apply chain spray.
Offroad chain spray ( p. 183)
Checking the chain tension

9.24
Warning
Danger of accidents Danger caused by incorrect chain tension.
– If the chain tension is too high, the components of the secondary power train (chain, engine sprocket, rear sprocket, bearings
in transmission and rear wheel) are under additional load. Apart from premature wear, in extreme cases the chain can rupture
or the countershaft of the transmission can break. On the other hand, if the chain is loose, it can fall off the engine sprocket or
the rear sprocket and block the rear wheel or damage the engine. Check for correct chain tension and adjust if necessary.
– Lean the motorcycle on the side stand.

– Push the chain upward at a distance  from the chain sliding guard and determine the
chain tension .
Info
The upper chain section  must be taut.
Chain wear is not always even, so you should repeat this measurement at differ-
ent chain positions.
Chain tension 5 mm (0.2 in)
Distance to chain sliding guard 30 mm (1.18 in)

» If the chain tension does not meet specifications:
– Adjust the chain tension. ( p. 81)
100249-10
Adjusting the chain tension

9.25
Warning
Danger of accidents Danger caused by incorrect chain tension.
– If the chain tension is too high, the components of the secondary power train (chain, engine sprocket, rear sprocket, bearings
in transmission and rear wheel) are under additional load. Apart from premature wear, in extreme cases the chain can rupture
or the countershaft of the transmission can break. On the other hand, if the chain is loose, it can fall off the engine sprocket or
the rear sprocket and block the rear wheel or damage the engine. Check for correct chain tension and adjust if necessary.
– Check the chain tension. ( p. 80)

– Loosen nut .
– Loosen nuts .
– Adjust the chain tension by turning adjusting screws  on the left and right.
Guideline
Chain tension 5 mm (0.2 in)
Turn the left and right adjusting screws  so that the markings on the left and right
chain adjusters  are in the same position relative to the reference marks . The
rear wheel is then correctly aligned.
Info
The upper chain section must be taut.
Chain wear is not always even, so you should check this setting at different
chain positions.
– Tighten nuts .
– Make sure that the chain adjusters  are installed correctly on adjusting screws .
– Tighten nut .
Guideline
100250-10 Nut, rear wheel spindle M25x1.5 90 Nm
(66.4 lbf ft)
Info
The wide adjustment range of the chain adjusters (30 mm (1.18 in)) enables
different secondary transmissions with the same chain length.
The chain adjusters  can be turned through 180°.
Checking rear sprocket / engine sprocket for wear

9.26
– Check rear sprocket / engine sprocket for wear.

» If the rear sprocket / engine sprocket are worn:
– Replace rear sprocket / engine sprocket.
Info
The engine sprocket, rear sprocket and chain should always be replaced
together.
For safety reasons, the chain has no chain joint. Always have the chain
replaced in an authorized KTM workshop, where the necessary chain
100132-10 rivet tool is available.
– Check chain guides for tightness and wear.

Checking chain wear

9.27
– Shift into neutral, pull the lower chain section with the specified weight .
Guideline
Weight of chain wear measurement 15 kg (33 lb.)
– Measure the distance  of 18 chain links in the lower chain section.
Info
Chain wear is not always even, so you should repeat this measurement at differ-
ent chain positions.
A
Maximum distance  at the longest 272 mm (10.71 in)
chain section
» If the distance  is greater than the specified measurement:
– Have the chain changed.
B Info
When the chain is replaced, the rear sprocket and engine sprocket
should also be changed.
New chains wear out faster on old, worn sprockets.
1 2 3 16 17 18 For safety reasons, the chain has no chain joint. Always have the chain
400409-10 changed in an authorized KTM workshop, where the necessary tool is
available.
Adjusting chain guide

9.28 x
– Remove screws  and . Take off the chain guide.
Condition
Number of teeth: ≤ 44 teeth
– Insert nut  in hole . Position the chain guide.
– Mount and tighten screws  and .
Guideline
Condition
Number of teeth: ≥ 45 teeth
– Insert nut  in hole . Position the chain guide.
– Mount and tighten screws  and .
Guideline
100299-10
Checking the brake discs

9.29
Warning
Danger of accidents Reduced braking due to worn brake discs.
– Worn brake discs should be replaced immediately in an authorized KTM workshop.
– Check the thickness of the front and rear brake discs in several places to ensure that it
conforms to measurement .
Info
Wear reduces the thickness of the brake disc at the contact surface  of the
brake disc.
Brake discs - wear limit

Front 4.5 mm (0.177 in)
400406-10 Rear 3.5 mm (0.138 in)
» If the brake disc thickness is less than the specified value:
– Replace the brake disc.
– Check the front and rear brake discs for damage, cracks, and deformation.
» If damage, cracks, or deformation are visible on the brake disc:
– Replace the brake disc.
Checking the free play of hand brake lever

9.30
Warning
– If there is no free travel on the hand brake lever, pressure builds up on the front brake in the brake system. The front brake can
fail due to overheating. Adjust free travel on hand brake lever according to specifications.
– Push the hand brake to the handlebar and check free play .
Free play of hand brake lever ≥ 3 mm (≥ 0.12 in)
» If the free travel does not meet specifications:
– Adjust the free travel of the handbrake lever. ( p. 87)
100251-10
Adjusting free travel of handbrake lever

9.31
– Adjust the free travel of the handbrake lever with the adjustment screw .
Info
Turn the adjustment screw clockwise to reduce free travel. The pressure point
moves away from the handlebar.
Turn the adjustment screw counterclockwise to increase free travel. The pressure
point moves towards the handlebar.
The range of adjustment is limited.
Turn the adjusting screw by hand only, and do not apply any force.
Do not make any adjustments while riding!
100252-10
– Check the free play of the hand brake lever. ( p. 86)

Checking the front brake fluid level

9.32
Warning
– If the brake fluid level falls below the MIN mark, this indicates a leakage in the brake system or worn-out brake linings. Have
the brake system checked in an authorized KTM workshop, and do not ride any further.
Warning
Danger of accidents Reduced braking due to old brake fluid.
– Have the front and rear brake fluid replaced according to the service plan in an authorized KTM workshop.
– Move the brake fluid reservoir mounted on the handlebar to a horizontal position.
– Check the brake fluid level in the viewer .
» If the brake fluid level is below the MIN mark:
– Add front brake fluid. x( p. 88)
100253-10
Adding front brake fluid

9.33 x
Warning
Warning
Skin irritations Brake fluid can cause skin irritation on contact.
– Avoid contact with skin and eyes, and keep out of the reach of children.
– If brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately.
Warning
Warning
Info
Never user DOT 5 brake fluid! This is based on silicone oil and is colored purple. Oil seals and brake lines are not designed for
DOT 5 brake fluid.
Avoid contact between brake fluid and painted parts. Brake fluid attacks paint!
Use only clean brake fluid from a sealed container!
– Remove screws .
– Remove cover  with membrane .
– Add brake fluid to level .
Guideline
Level  5 mm (0.2 in)
Brake fluid DOT 4 / DOT 5.1 ( p. 178)

– Position the cover with the membrane. Mount and tighten the screws.
100254-10
Info
Clean up overflowed or spilt brake fluid immediately with water.
Checking the front brake linings

9.34
Warning
Danger of accidents Reduced braking due to worn brake linings.
– Worn brake linings should be replaced immediately in an authorized KTM workshop.
Note
Danger of accidents Reduced braking due to damaged brake discs.
– If the brake linings are not changed in time, the steel brake lining carriers grind on the brake disc. The braking effect is greatly
reduced and the brake discs are destroyed.
– Check the brake linings for minimum thickness .

Minimum thickness  ≥ 1 mm (≥ 0.04 in)
» If the minimum thickness is less than specified:
– Change the front brake linings. x( p. 91)
– Check the brake linings for damage and cracking.
» If there is wear or tearing:
– Change the front brake linings. x( p. 91)
800076-10
Changing the front brake linings

9.35 x
Warning
Danger of accidents Improper brake maintenance and repair.
– Always have your brake system maintained and repaired in an authorized KTM workshop.
Warning
Warning
Warning
Warning
Danger of accidents Reduced braking due to use of non-approved brake linings.
– Brake linings available from accessory suppliers are often not tested and approved for use on KTM vehicles. The construction
and friction factor of the brake linings and therefore the brake power can differ considerably from the original KTM brake lin-
ings. If brake linings are used that differ from the originals, there is no guarantee that they comply with the original license.
The vehicle no longer corresponds to the condition at delivery, and the warranty is no longer valid.
Warning
Info
DOT 5 brake fluid.
– Press the brake caliper by hand on to the brake disc in order to press back the brake
pistons. Make sure that no brake fluid escapes from the brake fluid reservoir. If it does,
clean it up.
Info
Make sure when pushing back the brake pistons that you do not press the brake
100254-11 caliper against the spokes.
– Remove the safety clip , knock the pin  out to the right, and remove the brake lin-
ings.
– Clean brake caliper and brake caliper support.
400418-11
– Check that leaf spring  in the brake caliper and sliding plate  in the brake caliper
support are seated correctly.
400418-10
– Insert the brake pads, insert the bolt and mount the split pin.
– Operate the hand brake lever repeatedly until the brake linings lie on the brake disc and
there is a tight spot.
800077-10
– Add brake fluid level to .

Guideline
Level  5 mm (0.2 in)

Info
100254-12
Checking free play of foot brake lever

9.36
Warning
– If there is no free travel on the foot brake pedal, pressure builds up on the rear brake in the brake system. The rear brake can
fail due to overheating. Adjust free travel on foot brake pedal according to specifications.
– Move the foot brake lever back and forth between the end stop and the contact to the
foot brake cylinder piston and check free travel .
Guideline
Free play at foot brake lever 3… 5 mm (0.12… 0.2 in)
Info
You will know that contact has been made with the foot brake cylinder piston
when there is increased resistance when you activate the foot brake pedal.
100256-10 » If the free travel does not meet specifications:
– Adjust the basic position of the footbrake lever. x( p. 95)
Adjusting basic position of footbrake lever

9.37 x
Warning
– If there is no free travel on the foot brake pedal, pressure builds up on the rear brake in the brake system. The rear brake can
fail due to overheating. Adjust free travel on foot brake pedal according to specifications.
– Remove screws  on foot brake cylinder .

– To adjust the basic position of the footbrake lever individually, loosen nut  and turn
screw  accordingly.
Info
The range of adjustment is limited. The screw must be screwed into the footrest
bracket by at least four turns.
– Position foot brake cylinder  so that the foot brake pedal has the necessary free
travel. Hold screws  in place and tighten the nuts.
Guideline
Nut, foot brake cylinder screw M6 10 Nm (7.4 lbf ft)
– Check the free play of the foot brake lever. ( p. 94)
– Tighten nut .
100257-10
Checking rear brake fluid level

9.38
Warning
Warning
– Stand the vehicle upright.

– Check the brake fluid level in the brake fluid reservoir.
» If the fluid level reaches the MIN marking :
– Add rear brake fluid. x( p. 96)
100258-10
Adding rear brake fluid

9.39 x
Warning
Warning
Warning
Warning
Info
DOT 5 brake fluid.

– Remove the screw cap  with the membrane .
– Add brake fluid to MAX mark.
– Mount the screw cap with the membrane.
Info
100259-10
Checking the rear brake linings

9.40
Warning
Danger of accidents Reduced braking due to worn brake linings.
– Worn brake linings should be replaced immediately in an authorized KTM workshop.
Note
– If the brake linings are not changed in time, the steel brake lining carriers grind on the brake disc. The braking effect is greatly
reduced and the brake discs are destroyed.
– Check the brake linings for minimum thickness .

Minimum thickness  ≥ 1 mm (≥ 0.04 in)
» If the minimum thickness is less than specified:
– Change the rear brake linings. x( p. 98)
– Check the brake linings for damage and cracking.
» If there is wear or tearing:
– Change the rear brake linings. x( p. 98)
100260-10
Changing the rear brake linings

9.41 x
Warning
Danger of accidents Improper brake maintenance and repair.
– Always have your brake system maintained and repaired in an authorized KTM workshop.
Warning
Warning
Warning
Warning
Danger of accidents Reduced braking due to use of non-approved brake linings.
– Brake linings available from accessory suppliers are often not tested and approved for use on KTM vehicles. The construction
and friction factor of the brake linings and therefore the brake power can differ considerably from the original KTM brake lin-
ings. If brake linings are used that differ from the originals, there is no guarantee that they comply with the original license.
The vehicle no longer corresponds to the condition at delivery, and the warranty is no longer valid.
Warning
Info
DOT 5 brake fluid.

– Remove the screw cap  with the membrane .
piston. Make sure that no brake fluid escapes from the brake fluid reservoir. If it does,
clean it up.
Info
Make sure when pushing back the brake piston that you do not press the brake
caliper against the spokes.
100259-10
– Remove the safety clip , knock the pin  out to the left, and remove the brake lin-
ings.
– Clean brake caliper and brake caliper support.
100288-10
– Check that leaf spring  in the brake caliper and sliding plate  in the brake caliper
support are seated correctly.
400419-10
– Insert the brake pads, insert the bolt and mount the split pin.
– Operate the foot brake lever repeatedly until the brake linings lie on the brake disc and
– Add brake fluid to the MAX mark.
– Mount the screw cap with the membrane.
Info
100289-01 Clean up overflowed or spilt brake fluid immediately with water.
Removing the front wheel

9.42 x
pistons.
800078-10
– Remove screw .
– Loosen screw .
800079-10
– Holding the front wheel, withdraw the wheel spindle. Take the front wheel out of the
fork.
Info
Do not pull the hand brake lever when the front wheel is removed.
Always lay the wheel down in such a way that the brake disc is not damaged.
100263-10
– Remove distance bushings .
800080-10
Installing the front wheel

9.43 x
Warning
– Clean and grease the shaft seal rings  and bearing surface  of the distance bush-
ings.
Long-life grease ( p. 183)
– Insert the distance bushings.
800080-11
– Lift the front wheel into the fork, position it, and insert the wheel spindle.
– Mount and tighten screw .
Guideline
Screw, front wheel spindle M24x1.5 40 Nm
(29.5 lbf ft)
– Operate the hand brake lever several times until the brake pads are lying correctly on
the brake disc.
800079-11
– Pull the front wheel brake and push down hard on the fork several times to align the
fork legs.
– Fully tighten the screws .

Guideline
Screw, fork stub M8 15 Nm
(11.1 lbf ft)
Removing rear wheel

9.44 x
piston.
– Remove nut . Remove chain adjuster .
– Holding the rear wheel, withdraw the wheel spindle .
100267-10
– Push the rear wheel forwards as far as possible and take the chain off the rear sprocket.
Warning
– Always lay the wheel down in such a way that the brake disc is not damaged.
– Take the rear wheel out of the swing arm.
Info
100268-01 Do not operate the foot brake when the rear wheel is removed.
Installing the rear wheel

9.45 x
Warning
Warning
Danger of accidents No braking effect when operating the rear brake.
– After installing the rear wheel, always operate the footbrake until the pressure point is reached.
– Check the rear hub rubber dampers. x( p. 106)

– Remove the bushing . Clean and grease the working surfaces of the bushing and shaft
seal ring .
– Clean and grease the thread of the wheel spindle and nut .
– Install the rubber damper and rear sprocket carrier in the rear wheel.
– Place the rear wheel in the swingarm and bring the brake disc on the brake caliper into
100269-10 contact.
– Push the rear wheel forward as far as possible and lay the chain on the rear sprocket.
– Mount the wheel spindle, chain adjusters and nuts.
Guideline
In order that the rear wheel is correctly aligned, the markings on the left and right
chain adjusters must be in the same position relative to the reference marks .
Info
Mount the left and right chain adjusters  in the same position.
100270-10
– Tighten nut .
Guideline
Nut, rear wheel spindle M25x1.5 90 Nm
(66.4 lbf ft)
– Operate the foot brake lever repeatedly until the brake linings lie on the brake disc and
Checking the rear hub rubber dampers

9.46 x
Info
The engine power is transmitted from the rear sprocket to the rear wheel via 6 rubber dampers. They eventually wear out during
operation. If the rubber dampers are not changed in time, the rear sprocket carrier and the rear hub will be damaged.
– Remove the rear wheel. x( p. 104)

– Check the rubber dampers  of the rear hub for damage and wear.
» If the rubber dampers of the rear hub are damaged or worn:
– Change all rubber dampers in the rear hub.
100271-10
– Lay the read wheel on a workbench with the rear sprocket facing upwards and insert the
wheel spindle in the hub.
– To check the play , hold the rear wheel tight and try to rotate the rear sprocket.
Info
Measure the play on the outside of the rear sprocket.
Play in rubber dampers, rear wheel ≤ 5 mm (≤ 0.2 in)

» If clearance  is larger than the specified value:
100272-10
– Change all rubber dampers in the rear hub.
– Install the rear wheel. x( p. 105)
Checking the tire condition

9.47
Warning
Danger of accidents Uncontrollable handling behavior caused by a flat tire.
– For your own safety, have damaged tires changed immediately.
Warning
Danger of crashing Impairment of riding behavior due to different tire tread patterns on front and rear wheels.
– The front and rear wheels must be fitted with tires with similar tread patterns to prevent loss of control over the vehicle.
Warning
Danger of accidents Uncontrollable handling characteristics due to non-approved and/or non-recommended tires/wheels.
– Only tires/wheels approved by KTM and with the corresponding speed index should be used.
Warning
has been run in.
Info
The type, condition and air pressure of the tires all have an important impact on the riding behavior of the motorcycle.
Worn tires have a negative effect on riding behavior, especially on wet surfaces.
– Check the front and rear tires for cuts, run-in objects and other damage.
» If the tires exhibit cuts, run-in objects or other damage:
– Change the tires.
400602-10
– Check the depth of the tread.
Info
Note local national regulations concerning the minimum tread depth.
Minimum tread depth ≥ 2 mm (≥ 0.08 in)

» If the tread depth is less than the minimum permissible depth:
– Check the age of the tires.
Info
The tire's date of the manufacture is usually part of the tire markings and is
indicated by the last four digits of the DOT marking. The first two digits refer to
the week of manufacture and last two digits refer to the year of manufacture.
KTM recommends that the tires are changed regardless of the actual wear, at
the latest after 5 years.
» If a tire is more than 5 years old:

Checking the tire air pressure

9.48
Info
Low tire air pressure leads to abnormal wear and overheating of the tire.
Correct tire air pressure ensures optimal riding comfort and maximum tire service life.
– Remove dust cap.

– Check tire air pressure when tires are cold.
Tire air pressure, offroad, single rider
Front 1.5 bar (22 psi)
Rear 1.5 bar (22 psi)
Tire air pressure, road, solo

800081-10
Tire air pressure with passenger / fully loaded

» If the tire pressure does not meet specifications:
– Correct tire pressure.
– Mount dust cap.
Checking spoke tension

9.49
Warning
Danger of accidents Unstable riding behavior due to loose spokes.
– If you ride with loose spokes, the spokes can break. Have the spoke tension corrected in an authorized KTM workshop.
Info
A loose spoke can cause wheel imbalance, which leads to more loose spokes in a short time.
If the spokes are too tight, they can break due to local overload.
Check the spoke tension regularly, especially on a new motorcycle.
– To check spoke tension, tap each spoke with a screwdriver.

Guideline
You should hear a high note.
Spoke nipple, front wheel M4.5 5 Nm (3.7 lbf ft)

Spoke nipple, rear wheel M5 4 Nm (3 lbf ft)
Info
If you hear different tone frequencies from different spokes, this is an indication
800082-10
of different spoke tensions.
Removing the seat

9.50
– Pull on strap  and raise the rear of the seat at the same time.
– Pull back the seat and lift it off.
100230-10
Mounting the seat

9.51
– Hook slot  of the seat onto screw , press the rear downward and at the same time
push it forward.
– Push locking pin  into lock housing  and push the back of the seat down until the
locking pin locks in place with an audible click.
– Finally, check that the seat is correctly mounted.
800096-10
Removing the battery

9.52 x
Warning
Risk of injury Battery acid and battery gases cause serious chemical burns.
– Keep batteries out of the reach of children.
– Wear suitable protective clothing and goggles.
– Avoid contact with battery acid and battery gases.
– Keep the battery away from sparks or open fire. Charge only in well-ventilated rooms.
– In the event of skin contact, rinse with large amounts of water. If battery acid gets in the eyes, rinse with water for at least 15
minutes and contact a physician.
– Switch off all power consumers and switch off the engine.
– Remove the seat. ( p. 111)
– Disconnect the negative (minus) cable of the battery.

– Pull off the plug connector  upwards.
– Remove screws .
– Pull the retaining bracket  of the battery forward and remove it.
– Take off the positive pole cover .
– Disconnect the positive (plus) cable of the battery.
– Push the wiring harness to the side and pull the battery out of the battery rack.
100277-10 Info
Never operate the motorcycle with a discharged battery or without a battery. In
both cases, electrical components and safety devices can be damaged. The vehi-
cle is therefore no longer roadworthy.
Installing the battery

9.53 x
– Slide the battery into the battery rack.
Info
The battery terminals must be at the rear.
– Attach the positive cable and mount positive terminal cover .

– Position retaining bracket .
– Mount and tighten screws .
Guideline
100277-11
– Plug in connector .
– Attach the minus cable .
– Mount the seat. ( p. 112)
– Set the clock. ( p. 35)
Recharging the battery

9.54 x
Warning
Risk of injury Battery acid and battery gases cause serious chemical burns.
– Keep batteries out of the reach of children.
– Wear suitable protective clothing and goggles.
– Avoid contact with battery acid and battery gases.
– Keep the battery away from sparks or open fire. Charge only in well-ventilated rooms.
– In the event of skin contact, rinse with large amounts of water. If battery acid gets in the eyes, rinse with water for at least 15
minutes and contact a physician.
Warning
Environmental hazard Battery parts and acid are harmful to the environment.
– Do not discard batteries with the household trash. Dispose of a defective battery in an environmentally compatible manner.
Give the battery to your KTM dealer or to a recycling center that accepts used batteries.
Warning
Info
Even if there is no load on the battery, it loses power every day.
The charge state and the type of charge are very important for the service life of the battery.
Fast recharging with a high charge current shortens the battery's service life.
If the charge current, the charge voltage and the charge time are exceeded, electrolyte escapes through the breathing holes. The
battery capacity is then reduced.
If the battery is discharged from starting, it must be recharged immediately.
If it stands for a long time in a discharged state, the battery becomes over-discharged and sulfated, and then it is destroyed.
The battery is maintenance-free, i.e., the acid level does not have to be checked.
– Remove the battery. x( p. 112)
– Connect the battery charger to the battery. Switch on the battery charger.
Battery charger (58429074000)
You can also use the battery charger to test rest potential and start potential of the bat-
tery, and to test the generator. With this device, you cannot overcharge the battery.
Info
Never remove lid .
Charge the battery with a maximum of 10% of the capacity specified on the bat-
tery housing .
– Switch off and disconnect the charger after charging.

Guideline
The charge current, charge voltage and charge time must not be exceeded.
Charging the battery regularly when the 3 months
motorcycle is not in use
– Install the battery. x( p. 113)
100151-10
Changing the main fuse

9.55
Warning
Fire hazard The electrical system can be overloaded by the use of incorrect fuses.
– Use only fuses with the prescribed amperage. Never by-pass or repair fuses.
Info
The main fuse protects all power consumers on the vehicle. It is in the starter relay housing, next to the battery.
– Remove protection covers .
600604-10
– Use a needle nose plier to remove a defective main fuse .

– Insert the new main fuse.
Fuse (58011109130) ( p. 170)
Info
If the new fuse burns out, contact an authorized KTM workshop.
A reserve fuse  is located in the starter relay.
– Check that the electrical equipment is functioning properly.

600605-10
– Mount the protection covers.
Changing the fuses of power consumers

9.56
Info
The fuse box containing the fuses of the individual power consumers is located under the seat.
– Open fuse box cover .
600604-11
– Remove the defective fuse.

Guideline
Fuse 1 - 10A - ignition, combination instrument, alarm system (optional)
Fuse 2 - 10A - clock, ignition (EFI control unit)
Fuse 3 - 10A - throttle valve control unit
Fuse 4 - 10A - fuel pump
Fuse 5 - 10A - radiator fan
Fuse 6 - 10A - horn, brake light, flasher light, alarm system (optional)
Fuse 7 - 15A - high beam, low beam, parking light, tail light, license plate lamp
Fuse 8 - 10A - for accessories (in circuit with positive of ignition switch)
Fuse 9 - 10A - for accessories (permanent positive)
Fuse 10 - Not assigned
SPARE - 10A/15A - spare fuses
Info
You can recognize a defective fuse by the burned-out fuse wire .
600606-10
Warning
Fire hazard The electrical system can be overloaded by the use of incorrect
fuses.
– Use only fuses with the prescribed amperage. Never by-pass or repair fuses.
– Replace with a spare fuse of the right rating.

Fuse (75011088010) ( p. 170)
Fuse (75011088015) ( p. 170)
Info
If the new fuse burns out, contact an authorized KTM workshop.
Tip
Put a new spare fuse in the fuse box for future use if needed.
– Checking the function of power consumers.

– Close the fuse box cover.
Adjusting the engine characteristic

9.57
– Switch off the ignition by turning the ignition key to position OFF .
– Pull the Map‑Select switch and holder  upward off of the retaining bracket.
– Pull the Map‑Select switch out of the holder.
100237-10
– Turn the adjusting wheel until the desired digit is next to marking .
Set the Map‑Select switch to Soft.
– Set the adjusting wheel to position 1.
Soft – reduced homologated peak performance for better driveability.
Set the Map‑Select switch to Advanced.
Advanced – homologated performance with extremely direct responsiveness.
Set the Map‑Select switch to Standard.
100238-10 – Set the adjusting wheel to position 3, 4, 5, 6, 7, 8 or 9.
Standard – homologated performance with balanced responsiveness.
Set the Map‑Select switch to poor fuel quality.
Poor fuel quality – homologated performance is reduced in accordance with the
fuel quality, use for no more than 1 tank of fuel
– Position the Map‑Select switch in the holder.
– Slide the Map‑Select switch with the holder downward onto the retaining bracket.
Headlight mask, removing with headlight

9.58
– Remove screw  and take off the clamp.
– Release rubber band . Slide the headlight mask upward and tilt it forward.
800097-10
– Disconnect the electrical plug-in connection  and remove the headlight mask with the
headlight.
800102-10
Installing the headlight mask with the headlight

9.59
– Connect the electrical plug-in connection .
800102-11
– Position the headlight mask and fix it with rubber band .
Info
Make sure that the holding lugs engage in the fender.
– Position the brake line and cable harness. Position the clamp, and mount and tighten
screw .
800097-11
Changing the headlight bulb

9.60
Note
Damage to reflector Keep the glass of the bulb free of grease.
– Clean the glass bulb with a clean cloth before mounting. Any grease on the glass will evaporate due to the heat and be deposited on
the reflector.
– Remove the headlight mask with the headlight. ( p. 122)

– Pull off connectors ,  and .

– Take off rubber cap  of the headlight bulb.
800098-10
– Turn holder  about 30° counterclockwise and remove it.

– Remove headlight bulb.
– Insert a headlight bulb in the holder.
Headlight (BA20d) ( p. 170)
– Insert the holder into the headlight housing and fix it by turning it approx. 30° clock-
wise.
– Replace the rubber cap. Attach the connector.
800099-10
– Install the headlight mask with the headlight. ( p. 123)
Changing the parking light bulb

9.61
Note
the reflector.
– Remove the headlight mask with the headlight. ( p. 122)

– Pull bulb socket  out of the reflector.

– Pull parking light bulb  out of the bulb socket.
– Insert a new parking light bulb in the bulb socket.
Parking light (W2.1x9.5d) ( p. 170)
– Insert the bulb socket in the reflector.
– Install the headlight mask with the headlight. ( p. 123)
800100-10
Changing the flasher bulb

9.62
Note
the reflector.
– Remove the screw on the rear of the flasher housing.

– Tilt headlamp diffuser  forward carefully and take it off.
– Press the flasher bulb carefully into the socket, turn it counterclockwise by about 30°,
and take it out of the socket.
Info
Do not touch the reflector with your fingers, and keep it free from grease.
– Press the new flasher bulb carefully into the socket and turn it clockwise until it stops.
100160-10
Flasher light (BAU15s) ( p. 170)
– Position the diffuser.
– Insert the screw and turn it counterclockwise first until it engages in the thread. Tighten
the screw slightly.
– Check the flasher system function.
Check the headlamp setting

9.63
– On a light-colored wall behind a horizontal area, make a mark as high as the center of
0
A –
the low beam headlight.
Make another mark at a distance of  under the first mark.
Guideline
B
0 Distance  5 cm (2 in)
– Stand the motorcycle at a distance of  in front of the wall and switch on the low
beam.
Guideline
400408-10
Distance  5 m (16 ft)
– Check the headlamp setting.
The boundary between light and dark must be exactly on the lower mark for a motor-
cycle with driver.
» If the boundary between light and dark does not meet specifications:
– Adjust the headlight range. ( p. 127)
Adjusting the headlight range

9.64
– Check the headlamp setting. ( p. 127)

– Loosen screw .
– Adjust the light range by swiveling the headlight.
Guideline
For a motorcycle with rider, the light/dark boundary must be exactly on the lower
mark (made in: Checking headlight adjustment).
Info
If you have a heavy payload, you will need to correct the headlight range.
800101-10
– Tighten screw .
Removing the air filter

9.65 x
– Remove screws . Remove filter box top .
100285-10
Note
Engine failure Unfiltered intake air has a negative effect on the service life of the
engine.
– Never ride the vehicle without an air filter since dust and dirt can get into the
engine and result in increased wear.
– Remove air filter .
100286-10
Installing the air filter

9.66 x
– Clean the air filter box.
– Mount air filter .
Info
The air filter must lie flush against the air filter box along the entire sealing sur-
face .
If the air filter is not correctly mounted, dust and dirt can penetrate into the
engine and can cause damage.
100287-10
– Hook filter box top  into the front of the air filter box and swing down.
– Mount and tighten screws .

Guideline
Screw, air filter box top M6 2 Nm (1.5 lbf ft)
100285-11
Cooling system
9.67
The water pump  in the engine forces the coolant to flow.

The pressure resulting from the warming of the cooling system is regulated by a valve in
the radiator cap . Heat expansion causes excess coolant to flow into the compensating
tank . If the temperature falls, the excess coolant is sucked back into the cooling system.
The specified coolant temperature is therefore permissible without danger of function prob-
lems.
125 °C (257 °F)
600614-10
The coolant is cooled by the air stream and a radiator fan , which is controlled by a ther-
moswitch.
The lower the speed, the less the cooling effect. Dirty cooling fins also reduce the cooling
effect.
400407-10
Checking the antifreeze and coolant level

9.68
Warning
Scalding hazard During motorcycle operation, the coolant gets very hot and is under pressure.
– Do not open the radiator, the radiator hoses or other components of the cooling system when the engine is hot. Allow the engine
and radiator to cool down. If you are scalded, hold the affected part under cold water immediately.
Warning
Danger of poisoning Coolants are poisonous and a health hazard.
– Avoid contact between coolants and skin, eyes and clothing. If fuel gets into your eyes, rinse immediately with water and con-
tact a doctor. Wash affected skin areas immediately with soap and water. If coolant is swallowed, contact a doctor immediately.
Change clothes that have come into contact with coolants. Keep coolants out of the reach of children.
Condition
Engine is cold.
– Stand the motorcycle on its side stand on a horizontal surface.
– Remove the cap of the compensating tank .
– Check antifreeze of coolant.
−25… −45 °C (−13… −49 °F)
» If the antifreeze of the coolant does not meet specifications:
100283-10 – Correct the antifreeze of the coolant.
– Check the coolant level in the compensating tank.
The coolant level must be within the range shown in the figure.
» If the coolant level does not meet specifications:
– Correct the coolant level.
Alternative 1
Coolant ( p. 178)
Alternative 2
Coolant (mixed ready to use) ( p. 178)
– Mount the cap of the compensating tank.
– Screw off the radiator cap .

– Check antifreeze of coolant.
−25… −45 °C (−13… −49 °F)
» If the antifreeze of the coolant does not meet specifications:
– Correct the antifreeze of the coolant.
– Check the coolant level in the radiator.
The radiator must be completely filled.
100284-10
– Rectify the coolant level and find out the cause of the loss.
Alternative 1
Coolant ( p. 178)
Alternative 2
– Mount the radiator cap.
Checking the coolant level

9.69
Warning
Warning
Condition
Engine is cold.
– Check the coolant level in the compensating tank .
The coolant level must be within the range shown in the figure.
– Correct the coolant level.
100283-10 Alternative 1
Coolant ( p. 178)
Alternative 2
– Screw off the radiator cap  and check the coolant level in the radiator.
The radiator must be completely filled.
– Rectify the coolant level and find out the cause of the loss.
Alternative 1
Coolant ( p. 178)
Alternative 2
100284-10
– Mount the radiator cap.
Draining the coolant

9.70 x
Warning
Warning
– Remove the engine guard. ( p. 141)

– Stand the motorcycle upright.

– Place a suitable container under the engine.
– Remove screw . Remove the radiator cap.
– Completely drain the coolant.
– Mount the screw  with a new seal ring and tighten it.
Guideline
Plug, drain hole of water pump M10x1 15 Nm
(11.1 lbf ft)
600616-10
– Install the engine guard. ( p. 141)
Filling the cooling system

9.71 x
Warning

– Remove radiator cap .
600618-10
– Refill the coolant.

Alternative 1
Coolant ( p. 178)
Alternative 2
– Fill the radiator completely with coolant. Mount radiator cap .
600619-10
– Remove the cap from compensating tank  and add coolant to the level shown in the
figure.
– Mount the cap of the compensating tank.
Danger
Danger of poisoning Exhaust gases are poisonous and can result in
unconsciousness and/or death.
– When running the engine, always make sure there is sufficient ventilation,
and do not start or run the engine in a closed space without an effective
100283-11 exhaust extraction system.
– Start the engine and run it until the 5th bar of the temperature indicator lights up.
– Switch off the engine and allow it to cool down.
– After the engine has cooled down, check the coolant level in the radiator and in the
compensating tank again and add more coolant if necessary.
Adjusting basic position of clutch lever

9.72
Info
Turn the adjusting screw clockwise to increase the distance between the clutch lever and the handlebar.
Turn the adjusting screw counterclockwise to decrease the distance between the clutch lever and the handlebar.
The range of adjustment is limited.
Turn the adjusting screw by hand only, and do not apply any force.
Do not make any adjustments while riding!
– Adjust the basic setting of the clutch lever to your hand size by turning adjusting
screw .
– When adjusting the clutch lever make sure that there is a minimum clearance to other
parts of the vehicle.
Guideline
Minimum clearance 5 mm (0.2 in)
100282-10
Checking/rectifying the fluid level of the hydraulic clutch

9.73
Info
The fluid level rises with increasing wear of the clutch lining disc.
Do not use brake fluid.
– Move the clutch fluid reservoir mounted on the handlebar to a horizontal position.
– Check the fluid level.
Fluid level under top level of container 4 mm (0.16 in)
» If the level of the coolant does not meet specifications:
– Correct the fluid level of the hydraulic clutch.
Hydraulic fluid (15) ( p. 180)
100281-10
Checking the play in the gas Bowden cable

9.74
– Move the handlebar to the straight-ahead position. Move the throttle grip backwards
and forwards to ascertain the play in the gas Bowden cable.
Play in gas Bowden cable 3… 5 mm (0.12… 0.2 in)
» If the gas Bowden cable play does not meet specifications:
– Adjust the play in the gas Bowden cable. x( p. 140)
400192-10
Danger
exhaust extraction system.
– Start the engine and let it run idle. Move the handlebar to and fro over the entire steer-
ing range.
The idle speed must not change.
» If the idle speed changes:
– Adjust the play in the gas Bowden cable. x( p. 140)
Adjusting the play in the gas Bowden cable

9.75 x
– Move the handlebar to the straight-ahead position.
– Use the KTM diagnostics tool to set the throttle stepper motor to the neutral position.
– Loosen counter nut .
– Set the play in the gas Bowden cable by turning the adjusting screw .
Guideline
Play in gas Bowden cable 3… 5 mm (0.12… 0.2 in)
– Tighten counter nut .
100280-10
Removing the engine guard

9.76

– Remove screws  on the left and right.
– Pull the engine guard forward out of the holders and set it down.
100198-10
Installing the engine guard

9.77
– Slide the engine guard into holders  at the rear.

– Position the engine guard. Mount and tighten screws.
Guideline
100199-10
Checking the engine oil level

9.78
Info
The engine oil level must be checked when the engine is warm.
– Stand the motorcycle upright on a horizontal surface.

Condition
The engine is at operating temperature.
– Check the engine oil level.
Info
After switching off the engine, wait one minute before checking the level.
The engine oil must be between the lower and upper edge of the oil level viewer.
100210-10
» If the engine oil level is not at the specified level:
– Add the engine oil. ( p. 149)
Changing the engine oil and filter, cleaning the oil screens
9.79 x
– Drain the engine oil. x ( p. 143)
– Remove the oil filter. x ( p. 144)
– Clean the oil screens. x ( p. 146)
– Install the oil filter. x ( p. 146)
– Fill up with engine oil. x ( p. 148)
Draining the engine oil

9.80 x
Warning
Danger of scalding Engine oil and gear oil get very hot when the motocycle is driven.
– Wear suitable protective clothing and gloves. If you scald yourself, hold the affected area under cold water immediately.
Warning
Info
Drain the engine oil only when the engine is warm.
– Remove the engine guard. ( p. 141)

– Remove the oil drain plug  with the magnet and seal ring.
– Completely drain the engine oil.
100200-10
– Thoroughly clean the oil drain plug with a magnet.

– Mount the oil drain plug with the magnet and seal ring and tighten it.
Guideline
Oil drain plug with magnet M12x1.5 20 Nm
(14.8 lbf ft)
100201-01
Removing the oil filter

9.81 x
Warning
Warning

– Remove screws . Remove the oil filter cover  with the O-ring.
– Pull oil filter  out of the oil filter housing.
Circlip pliers reverse (51012011000)
100202-10
– Remove screws . Remove oil filter  with the O-ring.

– Pull oil filter  out of the oil filter housing.
Circlip pliers reverse (51012011000)
– Completely drain the engine oil.
– Thoroughly clean the parts and sealing area.
100203-10
Installing the oil filter

9.82 x
– Insert oil filters  and .
– Oil the O-rings of the oil filter cover. Fit the oil filter covers  and .
– Mount and tighten the screws.
Guideline
Screw, oil filter cover M5 6 Nm (4.4 lbf ft)
100204-10
Cleaning the oil screens

9.83 x
Warning
Warning

– Remove plug  with oil screen  and the O-rings.
100205-10
– Remove plug  with oil screen  and the O-rings.

– Completely drain the remaining engine oil.
– Thoroughly clean the parts and sealing area.
100206-10
– Position oil screen  with the O-rings.

– Mount and tighten plug  with the O-ring.
Guideline
Plug, oil screen M20x1.5 15 Nm
(11.1 lbf ft)
100207-10
– Position oil screen  with the O-rings.

– Mount and tighten plug  with the O-ring.
Guideline
Plug, oil screen M20x1.5 15 Nm
(11.1 lbf ft)
100208-10
Filling up with engine oil

9.84 x
Info
Too little engine oil or poor-quality engine oil results in premature wear to the engine.
– Remove filler plug with O-ring  from the clutch cover and add engine oil.
Engine oil 1.70 l (1.8 qt.) Engine oil (SAE 10W/60)
(00062010035) ( p. 179)
Alternative engine Engine oil
oil (SAE 10W/50)
( p. 179)
– Refit plug with O-ring  and tighten it.
100209-10
Danger
– Start the engine and check that it is oil-tight.

– Install the engine guard. ( p. 141)
Adding engine oil

9.85
Info
Too little engine oil or poor-quality engine oil results in premature wear to the engine.
– Remove the oil filler plug with O-ring  from the clutch cover and fill up with engine
oil.
Engine oil (SAE 10W/60) (00062010035) ( p. 179)
Engine oil (SAE 10W/50) ( p. 179)
Info
For optimal performance of the engine oil, do not mix different types of engine
oil.
100209-10
If appropriate, change the engine oil.
– Install and tighten the oil filler plug with O-ring .

Danger
– Start the engine and check that it is oil-tight.

TROUBLESHOOTING 151
Faults Possible cause Action

The engine does not turn when the Operating error – Carry out the start procedure. ( p. 49)
starter button is pressed Battery discharged – Recharge the battery. x( p. 114)
– Check the cause of discharging.
Fuse 1, 2, 3 or 4 is blown – Change the fuses of power consumers.
( p. 118)
Main fuse burned out – Changing the main fuse. ( p. 116)
Ignition/steering lock or emergency – Have ignition/steering lock or emergency OFF
OFF switch defective switch checked.
Defect in safety start system – Have the safety start system checked.
No ground connection present. – Check the ground connection.
Engine turns only if the clutch lever is The vehicle is in gear – Shift gear to neutral.
drawn The vehicle is in gear and the side – Shift gear to neutral.
stand is folded out
Defect in safety start system – Have the safety start system checked.
Engine turns although a gear is Defect in safety start system – Have the safety start system checked.
engaged
Engine turns but does not start. Operating error – Carry out the start procedure. ( p. 49)
Fuse 4 blown – Change the fuses of power consumers.
( p. 118)
Coupling of fuel hose connection not – Reconnect coupling of fuel hose connection.
connected
Socket connector of cable harness oxi- – Clean socket connector and treat it with contact
dized spray.
Defect in fuel injection system – Read the error memory with the KTM diagnostics
tool and correct the fault.
TROUBLESHOOTING 152

Engine has too little power. Air filter very dirty – Have the air filter changed.
Fuel filter very dirty – Have the fuel filter changed.
Defect in fuel injection system – Read the error memory with the KTM diagnostics
Engine overheats. Too little coolant in cooling system – Check the cooling system for leakage.
– Check the coolant level. ( p. 133)
Radiator fins very dirty – Clean radiator fins.
Foam formation in cooling system – Drain the coolant. x( p. 135)
– Fill the cooling system. x( p. 136)
Buckled or damaged radiator hose – Have the radiator hose changed.
Thermostat defective – Have thermostat checked.
Fuse 5 blown – Change the fuses of power consumers.
( p. 118)
Defect in radiator fan system – Have the radiator fan system checked.
Air in cooling system – Fill the cooling system. x( p. 136)
FI warning lamp (MIL) lights/flashes Defect in fuel injection system – Read the error memory with the KTM diagnostics
Engine dies during the journey Lack of fuel – Refuel. ( p. 57)
Fuse 1, 2 or 4 blown – Change the fuses of power consumers.
( p. 118)
High oil consumption Engine vent hose bent – Route the vent hose without bends or change it if
necessary.
Engine oil level too high – Check the engine oil level. ( p. 142)
Engine oil too thin (low viscosity) – Change the engine oil and filter, clean the oil
screens. ( p. 142)
x
TROUBLESHOOTING 153

Headlight and parking light not func- Fuse 7 blown – Change the fuses of power consumers.
tioning ( p. 118)
Flasher light, brake light and horn not Fuse 6 blown – Change the fuses of power consumers.
functioning ( p. 118)
Time is not (correctly) displayed Fuse 2 blown – Change the fuses of power consumers.
( p. 118)
Battery discharged Ignition not switched off when vehicle – Recharge the battery. x( p. 114)
was parked
Battery is not charged by generator – Check charging voltage.
Combination instrument shows nothing Fuse 1 blown – Change the fuses of power consumers.
in the display ( p. 118)
Speedometer in combination instru- Speedometer cable harness damaged – Have the cable harness and plug checked.
ment not functioning or plug oxidized
FLASHING CODE 154
Flashing code FI of warning lamp 02 FI warning lamp (MIL) flashes briefly 2x

(MIL)
Possible cause Malfunction in ignition pulse generator circuit

(MIL)
Possible cause Input signal of throttle valve sensor circuit A too low
Input signal of throttle valve sensor circuit A too high

(MIL)
Possible cause Input signal from throttle grip sensor too low
Input signal from throttle grip sensor too high

(MIL)
Possible cause Input signal from pressure sensor, induction manifold (cylinder 1) too low
Input signal from pressure sensor, induction manifold (cylinder 1) too high
Flashing code FI of warning lamp 12 FI warning lamp (MIL) flashes 1x long, 2x short
(MIL)
Possible cause Input signal from coolant temperature sensor too low
Input signal from coolant temperature sensor too high
FLASHING CODE 155
(MIL)
Possible cause Input signal from intake air temperature sensor too low
Input signal from intake air temperature sensor too high
(MIL)
Possible cause Input signal of pressure sensor ambient air too low
Input signal of pressure sensor ambient air too high
(MIL)
Possible cause Input signal from rollover sensor too low
Input signal from rollover sensor too high
(MIL)
Possible cause Malfunction in lambda probe circuit (cylinder 1)
(MIL)
Possible cause Malfunction in circuit of EFI control unit or EPT control unit voltage supply
(MIL)
Possible cause Malfunction in sidestand switch circuit
FLASHING CODE 156
(MIL)
Possible cause Malfunction in circuit of Hall sensor throttle valve control
(MIL)
Possible cause Malfunction in the EPT control unit power supply circuit
(MIL)
Possible cause Malfunction in injection valve circuit (cylinder 1)
(MIL)
Possible cause Malfunction in ignition coil circuit (cylinder 1)
(MIL)
Possible cause Interruption/short-circuit to ground in fuel pump control circuit
(MIL)
Possible cause Malfunction or short circuit to ground in lambda probe heating circuit (cylinder 1)
FLASHING CODE 157
(MIL)
Possible cause Interruption/short-circuit to ground in secondary air valve circuit
(MIL)
Possible cause Malfunction of release of throttle stepper motor in EPT mode
Flashing code FI of warning lamp 60 FI warning lamp (MIL) flashes 6x long

(MIL)
Possible cause Malfunction in throttle stepper motor circuit
(MIL)
Possible cause The connection of the manifold absolute pressure sensor (cylinder 1) is not airtight
Flashing code FI of warning lamp 90 FI warning lamp (MIL) flashes 9x long

(MIL)
Possible cause Throttle value position not plausible
(MIL)
Possible cause Malfunction in CAN bus communication
FLASHING CODE 158
(MIL)
Possible cause Malfunction in voltage supply circuit of EPT control unit (internal)
CLEANING 159
Cleaning motorcycle
12.1
Note
Material damage Damage and destruction of components by high-pressure cleaning equipment.
– Never clean the vehicle with high-pressure cleaning equipment or a strong water-jet. The excessive pressure can penetrate electrical
components, plug connectors, Bowden cables and bearings, etc., and can damage or destroy these parts.
Warning
Info
If you clean the motorcycle regularly, its value and appearance are maintained over a long period.
Avoid direct sunshine on the motorcycle during cleaning.
– Before you clean the motocycle, seal the exhaust system to prevent penetration by water.
– First remove coarse dirt particles with a gentle water spray.
– Spray very dirty areas with a normal motorcycle cleaner and then clean with a paintbrush.
Motorcycle cleaner ( p. 183)
Info
Use warm water containing normal motorcycle cleaner and a soft sponge.
If you have ridden the vehicle on salted roads, clean it with cold water. Warm water would reinforce the effect of the salt.
– After rinsing the motorcycle thoroughly with a soft jet of water, dry it with compressed air and a cloth.
CLEANING 160
Warning
Danger of accidents Reduced braking due to wet or dirty brakes.
– Clean or dry dirty or wet brakes by riding and braking gently.
– After cleaning, ride the vehicle a short distance until the engine warms up, and then apply the brakes.
Info
The heat produced causes water at inaccessible positions in the engine and the brakes to evaporate.
– Push back the protection covers on the handlebar instruments to allow water to evaporate.
– After the motorcycle has cooled off, oil or grease all moving parts and bearings.
– Treat bare metal parts (except for brake discs and exhaust system) with anti-corrosion materials.
Cleaning and polishing materials for metal, rubber and plastic ( p. 182)
– Treat all painted parts with a mild paint polish.
High-luster polish for paint ( p. 182)
– To prevent electrical problems, treat electric contacts and switches with contact spray.
Contact spray ( p. 182)
– Oil the ignition/steering lock.
Universal oil spray ( p. 183)
CONSERVING FOR WINTER OPERATION 161
Conservation for winter operation

13.1
Info
If you use the motorcycle in winter, you must expect salt on the roads. You should therefore take precautions against aggressive
road salt.
If you have ridden the vehicle on salted roads, clean it with cold water. Warm water would reinforce the effect of the salt.
– Clean the motorcycle. ( p. 159)

– Treat the engine, the swingarm, and all other bare or galvanized parts (except brake discs) with a wax-based anti-corrosion substance.
Info
To prevent serious reduction of the braking efficiency, make sure no anti-corrosion substance gets on to the brake discs.
After use on salted roads, clean the motorcycle thoroughly with cold water and dry it properly.

STORAGE 162
Storage
14.1
Info
If you want to garage the motorcycle for a longer period, take the following actions.
Before storing the motorcycle, check all parts for function and wear. If service, repairs or replacements are necessary, you should
do this during the storage period (less workshop overload). In this way, you can avoid long workshop waiting times at the start of the
new season.
– Make sure the tank is as empty as possible so that you can fill up with fresh fuel when you put the motorcycle back into operation.
– Clean the motorcycle. ( p. 159)
– Change the engine oil and filter, clean the oil screens. x( p. 142)
– Check the antifreeze and coolant level. ( p. 131)
– Check the tire air pressure. ( p. 109)
– Remove the battery. x( p. 112)
– Recharge the battery. x( p. 114)
Guideline
Storage temperature of battery without direct sunshine. 0… 35 °C (32… 95 °F)
– The storage place should be dry and not subject to large temperature differences.
Info
KTM recommends jacking up the motorcycle.

STORAGE 163
– Cover the motorcycle with a porous sheet or blanket.
Info
Do not use non-porous materials since they prevent humidity from escaping, thus causing corrosion.
Avoid running the engine for a short time only. Since the engine cannot warm up properly, the water vapor produced during
combustion condenses and causes valves and exhaust system to rust.
Putting into operation after storage

14.2

– Recharge the battery. x ( p. 114)
– Install the battery. x ( p. 113)
– Refuel. ( p. 57)
– Carry out checks before putting into operation. ( p. 48)
– Make a test ride.
TECHNICAL DATA - ENGINE 164
Design 1-cylinder 4-stroke engine, water-cooled

Displacement 654 cm³ (39.91 cu in)
Stroke 80 mm (3.15 in)
Bore 102 mm (4.02 in)
Compression ratio 11.8:1
Control OHC, 4 valves controlled via rocker arm, chain drive
Valve diameter, intake 40 mm (1.57 in)
Valve diameter, exhaust 34 mm (1.34 in)
Valve play, cold 0.07… 0.13 mm (0.0028… 0.0051 in)
Crankshaft bearing 2 roller bearings
Conrod bearing Needle bearing
Piston pin bearing Bronze bush
Pistons Forged light alloy
Piston rings 1 L-ring, 1 tapered compression piston ring, 1 oil scraper ring
Engine lubrication Semi-dry sump lubrication with two rotor pumps
Primary transmission 36:79
Clutch APTC™ Antihopping clutch in oil bath / hydraulically operated
Gearbox 6-gears, claw-shifted
Transmission ratio
1st gear 14:35
2nd gear 16:28
3rd gear 21:28
4th gear 21:23
5th gear 23:22
6th gear 23:20
TECHNICAL DATA - ENGINE 165
Mixture preparation Electronic fuel injection

Ignition Contactless controlled fully electronic ignition with digital ignition
adjustment
Generator 12 V, 224 W
Spark plug NGK LKAR 8AI - 9
Spark plug electrode gap 0.9 mm (0.035 in)
Cooling Water cooling, permanent circulation of coolant by water pump
Starting aid Electric starter, automatic decompressor
Capacity- engine oil

15.1
Engine oil 1.70 l (1.8 qt.) Engine oil (SAE 10W/60) (00062010035) ( p. 179)
Alternative engine oil Engine oil (SAE 10W/50)
( p. 179)
Capacity - coolant
15.2
Coolant 1.20 l (1.27 qt.) Coolant ( p. 178)

TECHNICAL DATA - ENGINE TIGHTENING TORQUES 166
Oil hole plug self-tapping 9 Nm (6.6 lbf ft) Loctite® 243™

Screw, membrane fixation M3 2.5 Nm (1.84 lbf ft) Loctite® 243™
Hose clamp, intake flange M4 1.5 Nm (1.11 lbf ft) –
Oil jet, conrod lubrication M4 2 Nm (1.5 lbf ft) Loctite® 243™
Locking screw for bearing M5 6 Nm (4.4 lbf ft) Loctite® 243™
Screw, breather cover on valve cover M5 3 Nm (2.2 lbf ft) Loctite® 243™
Screw, clutch spring M5 6 Nm (4.4 lbf ft) –
Screw, cover plate for oil return line M5 6 Nm (4.4 lbf ft) –
Screw, gear sensor M5 5 Nm (3.7 lbf ft) Loctite® 243™
Screw, oil filter cover M5 6 Nm (4.4 lbf ft) –
Screw, oil pump cover M5 6 Nm (4.4 lbf ft) Loctite® 243™
Plug, vacuum connection M6 10 Nm (7.4 lbf ft) Loctite® 243™
Screw, Autodecompression M6 3… 4 Nm (2.2… 3 lbf ft) Loctite® 243™
Screw, axial lock of camshaft M6 10 Nm (7.4 lbf ft) Loctite® 243™
Screw, clutch cover M6 10 Nm (7.4 lbf ft) –
Screw, clutch slave cylinder M6x20 10 Nm (7.4 lbf ft) Loctite® 243™
Screw, clutch slave cylinder M6x35 10 Nm (7.4 lbf ft) –
Screw, cylinder M6 10 Nm (7.4 lbf ft) Loctite® 243™
Screw, cylinder head M6 10 Nm (7.4 lbf ft) Loctite® 243™
Screw, engine housing M6 10 Nm (7.4 lbf ft) –
Screw, generator cover M6 10 Nm (7.4 lbf ft) –
Screw, generator cover (chain shaft M6 10 Nm (7.4 lbf ft) Loctite® 243™
through-hole)
Screw, ignition pulse generator M6 10 Nm (7.4 lbf ft) Loctite® 243™
Screw, locking lever M6 10 Nm (7.4 lbf ft) Loctite® 243™

Screw, rocker arm shaft M6 12 Nm (8.9 lbf ft) –
Screw, shift drum locating M6 10 Nm (7.4 lbf ft) Loctite® 243™
Screw, shift lever M6 10 Nm (7.4 lbf ft) Loctite® 222
Screw, starter motor M6 10 Nm (7.4 lbf ft) Loctite® 243™
Screw, stator bracket M6 10 Nm (7.4 lbf ft) Loctite® 243™
Screw, thermostat housing M6 10 Nm (7.4 lbf ft) Loctite® 243™
Screw, timing chain guide rail M6 10 Nm (7.4 lbf ft) Loctite® 243™
Screw, timing chain tensioning rail M6 10 Nm (7.4 lbf ft) Loctite® 243™
Screw, valve cover M6 10 Nm (7.4 lbf ft) –
Screw, water pump cover M6 10 Nm (7.4 lbf ft) –
Screw, water pump wheel M6 10 Nm (7.4 lbf ft) Loctite® 243™
Oil jet, piston cooling M6x0.75 4 Nm (3 lbf ft) Loctite® 243™
Plug, crankshaft location M8 20 Nm (14.8 lbf ft) –
Stud, exhaust flange M8 10 Nm (7.4 lbf ft) Loctite® 243™
Cylinder head screw M10 Tightening sequence: lubricated with engine oil
Tighten diagonally, beginning
with the rear screw on the
chain shaft.
Step 1
15 Nm (11.1 lbf ft)
Step 2
30 Nm (22.1 lbf ft)
Step 3
45 Nm (33.2 lbf ft)
Step 4
60 Nm (44.3 lbf ft)
Oil hole plug M10x1 15 Nm (11.1 lbf ft) Loctite® 243™

Plug, drain hole of water pump M10x1 15 Nm (11.1 lbf ft) –
Plug, oil bore for oil radiator M10x1 15 Nm (11.1 lbf ft) –
Screw, unlocking of timing chain ten- M10x1 10 Nm (7.4 lbf ft) –
sioner
Spark plug M12x1.25 17 Nm (12.5 lbf ft) –
Coolant temperature sensor on cylinder M12x1.5 12 Nm (8.9 lbf ft) –
head
Oil drain plug with magnet M12x1.5 20 Nm (14.8 lbf ft) –
Oil pressure regulator valve plug M12x1.5 20 Nm (14.8 lbf ft) –
Plug, oil bore M14x1.5 15 Nm (11.1 lbf ft) Loctite® 243™
Engine case stud M16x1.5 25 Nm (18.4 lbf ft) Loctite® 243™
Rotor nut M18x1.5 100 Nm (73.8 lbf ft) –
Nut, engine sprocket M20x1.5 60 Nm (44.3 lbf ft) Loctite® 243™
Nut, inner clutch hub M20x1.5 100 Nm (73.8 lbf ft) Loctite® 243™
Nut, primary gear M20LHx1.5 90 Nm (66.4 lbf ft) Loctite® 243™
Plug, oil screen M20x1.5 15 Nm (11.1 lbf ft) –
Plug, timing chain tensioner M20x1.5 25 Nm (18.4 lbf ft) –
Plug, oil thermostat M24x1.5 15 Nm (11.1 lbf ft) –
Screw in generator cover M24x1.5 8 Nm (5.9 lbf ft) –
TECHNICAL DATA - CHASSIS 169
Frame Lattice frame made of chrome molybdenum steel tubing, powder-

coated
Fork WP Suspension 4860 MXMA
Shock absorber WP Suspension 4618 with Pro‑Lever deflector
Suspension travel
Front 275 mm (10.83 in)
Rear 275 mm (10.83 in)
Brake system
Front Disc brake with dual-piston brake caliper, floating
Rear Disc brake with single-piston brake caliper, floating
Brake discs - diameter
Front 300 mm (11.81 in)
Rear 240 mm (9.45 in)
Brake discs - wear limit
Front 4.5 mm (0.177 in)
Rear 3.5 mm (0.138 in)
Tire air pressure, road, solo
Tire air pressure with passenger / fully loaded
Tire air pressure, offroad, single rider
Secondary drive ratio 15:45

Chain 5/8 x 1/4” X‑ring
Steering head angle 63°
Wheelbase 1,498±15 mm (58.98±0.59 in)
Seat height unloaded 930 mm (36.61 in)
Ground clearance unloaded 320 mm (12.6 in)
Weight without fuel approx. 138.5 kg (305.3 lb.)
Maximum permissible front axle load 150 kg (331 lb.)
Maximum permissible rear axle load 200 kg (441 lb.)
Maximum permissible overall weight 350 kg (772 lb.)
Battery YTZ10S Battery voltage: 12 V

Nominal capacity: 8.6 Ah
maintenance-free
Fuse 58011109130 30 A
Fuse 75011088015 15 A
Fuse 75011088010 10 A
Lighting equipment
17.1
Headlight BA20d 12 V
30/35 W
Parking light W2.1x9.5d 12 V
5W
Instrument lights and indicator lamps LED
Flasher light BAU15s 12 V
10 W
Brake / tail light BA15d 12 V

21/5 W
Tires
17.2
Front tire Rear tire

90/90 - 21 M/C 54R TT 140/80 - 18 M/C 70R TT
Pirelli MT 21 RALLYCROSS Pirelli MT 21 RALLYCROSS
Additional information is available in the Service section under:
http://www.ktm.com
Capacity - fuel
17.3
Total fuel tank capacity, approx. 12 l (3.2 US gal) Super unleaded (ROZ 95 / RON 95 / PON 91) ( p. 181)
Fuel reserve, approx. 2.5 l (2.6 qt.)

TECHNICAL DATA - FORK 172
Fork part number 14.18.7E.41

Fork WP Suspension 4860 MXMA
Compression damping
Comfort 20 clicks
Standard 15 clicks
Sport 10 clicks
Rebound damping
Comfort 20 clicks
Standard 15 clicks
Sport 10 clicks
Spring length with preload spacer(s) 495 mm (19.49 in)
Spring rate
Weight of rider: 75… 85 kg (165… 187 lb.) 5.2 N/mm (29.7 lb/in)
Air chamber length 100+0 +0
−20 mm (3.94−0.79 in)
Fork length 915 mm (36.02 in)
Fork oil 635 ml (21.47 fl. oz.) Fork oil (SAE 5) ( p. 180)
TECHNICAL DATA - SHOCK ABSORBER 173
Shock absorber part number 15.18.7E.41

Shock absorber WP Suspension 4618 with Pro‑Lever deflector
Compression damping, high-speed
Comfort 2 turns
Standard 1.5 turns
Sport 1 turn
Full payload 1 turn
Compression damping, low-speed
Comfort 20 clicks
Standard 15 clicks
Sport 10 clicks
Rebound damping
Comfort 20 clicks
Standard 15 clicks
Sport 10 clicks
Spring preload 20 mm (0.79 in)
Spring rate
Weight of rider: 75… 85 kg (165… 187 lb.) 80 N/mm (457 lb/in)
Spring length 220 mm (8.66 in)
Gas pressure 10 bar (145 psi)
Static sag 25 mm (0.98 in)
Riding sag 70… 80 mm (2.76… 3.15 in)
Fitted length 405 mm (15.94 in)
TECHNICAL DATA - SHOCK ABSORBER 174
Shock absorber oil ( p. 180) SAE 2.5

TECHNICAL DATA - CHASSIS TIGHTENING TORQUES 175
Screw, license plate holder, bottom 3 Nm (2.2 lbf ft) –

Screw, SLS valve 2 Nm (1.5 lbf ft) –
Spoke nipple, front wheel M4.5 5 Nm (3.7 lbf ft) –
Remaining screws, chassis M5 4 Nm (3 lbf ft) –
Screw, electrical holder M5 3 Nm (2.2 lbf ft) –
Screw, exhaust heat shield M5 8 Nm (5.9 lbf ft) –
Screw, footbrake pedal foothold M5 6 Nm (4.4 lbf ft) Loctite® 243™
Screw, fuel level indicator M5 3 Nm (2.2 lbf ft) –
Screw, fuel pump M5 6 Nm (4.4 lbf ft) –
Screw, headlight mask M5 5 Nm (3.7 lbf ft) –
Screw, seat lock M5 3 Nm (2.2 lbf ft) Loctite® 222
Screw, side cover M5 2 Nm (1.5 lbf ft) –
Screw, side stand switch M5 3 Nm (2.2 lbf ft) –
Screw, starter cable on starter M5 3 Nm (2.2 lbf ft) –
Spoke nipple, rear wheel M5 4 Nm (3 lbf ft) –
Nut, foot brake cylinder screw M6 10 Nm (7.4 lbf ft) –
Remaining nuts, chassis M6 15 Nm (11.1 lbf ft) –
Remaining screws on fuel tank M6 6 Nm (4.4 lbf ft) –
Remaining screws, chassis M6 10 Nm (7.4 lbf ft) –
Screw, air filter box top M6 2 Nm (1.5 lbf ft) –
Screw, ball joint of push rod on foot- M6 10 Nm (7.4 lbf ft) Loctite® 243™
brake cylinder
Screw, brake fluid reservoir of rear brake M6 5 Nm (3.7 lbf ft) –
Screw, front brake disc M6 14 Nm (10.3 lbf ft) Loctite® 243™
Screw, ignition lock M6 10 Nm (7.4 lbf ft) Loctite® 243™
Screw, magnetic holder on side stand M6 10 Nm (7.4 lbf ft) Loctite® 243™
Screw, radiator bracket M6 5 Nm (3.7 lbf ft) –
Screw, rear brake disc M6 14 Nm (10.3 lbf ft) Loctite® 243™
Screw, voltage regulator/rectifier M6 8 Nm (5.9 lbf ft) –
Nut, manifold on cylinder head M8 25 Nm (18.4 lbf ft) Copper paste
Nut, rear sprocket screw M8 35 Nm (25.8 lbf ft) Loctite® 243™
Screw, bottom triple clamp M8 12 Nm (8.9 lbf ft) –
Screw, connection lever on frame M8 30 Nm (22.1 lbf ft) –
Screw, exhaust clamp on main silencer M8 25 Nm (18.4 lbf ft) –
Screw, fork stub M8 15 Nm (11.1 lbf ft) –
Screw, front brake caliper M8 25 Nm (18.4 lbf ft) Loctite® 243™
Screw, front footrest bracket M8 25 Nm (18.4 lbf ft) –
Screw, fuel tank, bottom M8 20 Nm (14.8 lbf ft) –
Screw, handlebar clamp M8 20 Nm (14.8 lbf ft) Loctite® 243™
Screw, handrail M8 20 Nm (14.8 lbf ft) –
Screw, license plate holder, top M8 20 Nm (14.8 lbf ft) –
Screw, main silencer holder M8 25 Nm (18.4 lbf ft) –
Screw, main silencer holder on fuel tank M8 25 Nm (18.4 lbf ft) Loctite® 243™
Screw, rear footrest bracket M8x16 25 Nm (18.4 lbf ft) –
Screw, side stand bracket M8 25 Nm (18.4 lbf ft) –
Screw, spring holder on side stand M8 25 Nm (18.4 lbf ft) Loctite® 243™
bracket
Screw, steering stem M8 20 Nm (14.8 lbf ft) Loctite® 243™

Screw, top triple clamp M8 17 Nm (12.5 lbf ft) –
Upper fuel tank screw M8 20 Nm (14.8 lbf ft) –
Engine carrying screw M10 45 Nm (33.2 lbf ft) Loctite® 243™
Screw, bottom shock absorber M10 45 Nm (33.2 lbf ft) Loctite® 243™
Screw, engine bearer on frame M10 45 Nm (33.2 lbf ft) –
Screw, foot brake pedal M10LH 25 Nm (18.4 lbf ft) Loctite® 243™
Screw, handlebar support M10 40 Nm (29.5 lbf ft) –
Screw, side stand M10 35 Nm (25.8 lbf ft) Loctite® 243™
Screw, top shock absorber M10 45 Nm (33.2 lbf ft) Loctite® 243™
Lambda probe M12x1.25 24.5 Nm (18.07 lbf ft) Copper paste
Screw, swingarm pivot M12x1.75 80 Nm (59 lbf ft) –
Nut, linkage lever on swingarm M14x1.5 100 Nm (73.8 lbf ft) –
Nut, linkage lever to rocker arm M14x1.5 100 Nm (73.8 lbf ft) –
Screw, bottom steering head M20x1.5 60 Nm (44.3 lbf ft) Loctite® 243™
Screw, top steering head M20x1.5 10 Nm (7.4 lbf ft) –
Screw, front wheel spindle M24x1.5 40 Nm (29.5 lbf ft) –
Nut, rear wheel spindle M25x1.5 90 Nm (66.4 lbf ft) –
SUBSTANCES 178
Brake fluid DOT 4 / DOT 5.1

According to
– DOT
Guideline
– Use only brake fluid that complies with the specified standards (see specifications on the container) and that possesses the corre-
sponding properties. KTM recommends Castrol and Motorex® products.
Supplier
Castrol
– RESPONSE BRAKE FLUID SUPER DOT 4
Motorex®
– Brake Fluid DOT 5.1
Coolant
Guideline
– Use only suitable coolant (in countries with high temperatures also). Use of low-quality antifreeze can lead to corrosion and foaming.
KTM recommends Motorex® products.
Mixture ratio
Antifreeze protection: −25… −45 °C (−13… 50 % Corrosion/antifreeze
−49 °F) 50 % Distilled water
Coolant (mixed ready to use)

Antifreeze −40 °C (−40 °F)
Supplier
Motorex®
– Anti Freeze
SUBSTANCES 179
Engine oil (SAE 10W/60) (00062010035)

According to
– JASO T903 MA ( p. 184)
– SAE ( p. 184) (SAE 10W/60)
– KTM LC4 2007+
Guideline
– Use only engine oils that comply with the specified standards (see specifications on the container) and that possess the corresponding
properties. KTM recommends Motorex® products.
Synthetic engine oil
Supplier
Motorex®
– Motorex® KTM Cross Power 4T
Engine oil (SAE 10W/50)

According to
– JASO T903 MA ( p. 184)
– SAE ( p. 184) (SAE 10W/50)
Guideline
– Use only engine oils that comply with the specified standards (see specifications on the container) and that possess the corresponding
properties. KTM recommends Motorex® products.
Fully synthetic engine oil
Supplier
Motorex®
– Power Synt 4T
SUBSTANCES 180
Fork oil (SAE 5)

According to
– SAE ( p. 184) (SAE 5)
Guideline
– Use only oils that comply with the specified standards (see specifications on the container) and that possesses the corresponding prop-
erties. KTM recommends Motorex® products.
Supplier
Motorex®
– Racing Fork Oil
Hydraulic fluid (15)

According to
– ISO VG (15)
Guideline
– Use only hydraulic fluid that complies with the specified standards (see specifications on the container) and that possesses the corre-
sponding properties. KTM recommends Motorex® products.
Supplier
Motorex®
– Hydraulic Fluid 75
Shock absorber oil (SAE 2.5) (50180342S1)

According to
– SAE ( p. 184) (SAE 2.5)
Guideline
– Use only oils that comply with the specified standards (see specifications on the container) and that possess the corresponding proper-
ties.
SUBSTANCES 181
Super unleaded (ROZ 95 / RON 95 / PON 91)

According to
– DIN EN 228 (ROZ 95 / RON 95 / PON 91)
AUXILIARY SUBSTANCES 182
Chain cleaner
Specification
– KTM recommends Motorex® products.
Supplier
Motorex®
– Chain Clean 611
Cleaning and polishing materials for metal, rubber and plastic

Specification
Supplier
Motorex®
– Protect & Shine 645
Contact spray
Specification
Supplier
Motorex®
– Accu Contact
High-luster polish for paint

Specification
Supplier
Motorex®
– Moto Polish
AUXILIARY SUBSTANCES 183
Long-life grease
Specification
Supplier
Motorex®
– Fett 2000
Motorcycle cleaner
Specification
Supplier
Motorex®
– Moto Clean 900
Offroad chain spray

Specification
Supplier
Motorex®
– Chain Lube 622
Universal oil spray

Specification
Supplier
Motorex®
– Joker 440 Universal
STANDARDS 184
JASO T903 MA
Different technical development directions required a new specification for 4-stroke motorcycles – the JASO T903 MA Standard. Ear-
lier, engine oils from the automobile industry were used for 4-stroke motorcycles because there was no separate motorcycle specification.
Whereas long service intervals are demanded for automobile engines, high performance at high engine speeds are in the foreground for
motorcycle engines. With most motorcycles, the gearbox and the clutch are lubricated with the same oil as the engine. The JASO MA Stan-
dard meets these special requirements.
SAE
The SAE viscosity classes were defined by the Society of Automotive Engineers and are used for classifying oils according to their viscos-
ity. The viscosity describes only one property of oil and says nothing about quality.
INDEX 185
A Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Air filter C
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129 Chain
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128 checking for dirt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Antifreeze checking wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131 cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
B Chain guide
Baggage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Battery Chain tension

fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
recharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114 checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112 Chassis number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Brake discs Checking the headlamp setting . . . . . . . . . . . . . . . . . . . . . . 127
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159-160
Brake fluid Clutch

front brake, adding . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 checking/correcting fluid level . . . . . . . . . . . . . . . . . . . 138
rear brake, adding . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96 Clutch lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Brake fluid level basic position, adjusting . . . . . . . . . . . . . . . . . . . . . . . 138
front brake, checking . . . . . . . . . . . . . . . . . . . . . . . . . . 88 Combination instrument . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
rear brake, checking . . . . . . . . . . . . . . . . . . . . . . . . . . . 96 clock, setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Brake linings coolant temperature indicator . . . . . . . . . . . . . . . . . . . . . 38
front brake, changing . . . . . . . . . . . . . . . . . . . . . . . . . . 91 display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
front brake, checking . . . . . . . . . . . . . . . . . . . . . . . . . . 90 display ODO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
rear brake, changing . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 display TRIP F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
rear brake, checking . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 function buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
indicator lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
INDEX 186
setting kilometers or miles . . . .... . . . . . . . . . . . . . . . . 34 Engine oil

speed display . . . . . . . . . . . . .... . . . . . . . . . . . . . . . . 34 adding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
time . . . . . . . . . . . . . . . . . . .... . . . . . . . . . . . . . . . . 35 changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
TRIP 1 display, setting/resetting ... . . . . . . . . . . . . . . . . 36 draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
TRIP 2 display, setting/resetting ... . . . . . . . . . . . . . . . . 37 refilling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
Conservation for winter operation . . . . . . . . . . . . . . . . . . . . . 161 Engine oil level
Conserving for winter operation . . . . . . . . . . . . . . . . . . . . . . 161 checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
Coolant Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135 F
Coolant level
Filler cap
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131, 133
closing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130 opening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Flasher bulb
D changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Flasher switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
E Flashing code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154-158
Electric starter button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Foot brake pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Emergency OFF switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 basic position, adjusting . . . . . . . . . . . . . . . . . . . . . . . . 95
Engine checking free play . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
running in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Fork . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Engine characteristic compression damping, adjusting . . . . . . . . . . . . . . . . . . . 64
adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 dust boots, cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
fork legs, bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Engine guard
rebound, adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141 Fork part number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
INDEX 187
Fork protector Indicator lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

positioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 K
remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Key number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Front wheel
L
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101 Light switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Loading the vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Fuel, oils, etc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Fuse M
power consumers, changing . . . . . . . . . . . . . . . . . . . . . 118 Main fuse
H changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Hand brake lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
checking free play . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 Motorcycle
free travel, adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . 87 cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
jacking up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Handlebar position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
removing from the work stand . . . . . . . . . . . . . . . . . . . . . 63
adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Handrails . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 O
Headlight Oil filter

light range, adjusting . . . . . . . . . . . . . . . . . . . . . . . . . 127 changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
Headlight bulb, changing . . . . . . . . . . . . . . . . . . . . . . . . . . 124
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
Headlight mask with headlight
Oil screens
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142, 146
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Owner's manual
Horn button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
I
P
Ignition lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Parking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
INDEX 188
Parking light bulb Seat release . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125 Service plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59-62
Passenger footrests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Shift lever . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Shifting . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Play in gas Bowden cable
adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140 Shock absorber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139 adjusting rebound damping . . . . . . . . . . . . . . . . . . . . . . 69
compression damping, general . . . . . . . . . . . . . . . . . . . . 66
Putting into operation
compression damping, high-speed, adjusting . . . . . . . . . . 68
advice on first use . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
compression damping, low-speed, adjusting . . . . . . . . . . . 66
after storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
riding sag, checking . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
checks before putting into operation . . . . . . . . . . . . . . . . 48
static sag, checking . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
R
Shock absorber part number . . . . . . . . . . . . . . . . . . . . . . . . . 26
Rear hub rubber dampers Side stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106 Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Rear sprocket / engine sprocket Spoke tension
checking for wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Rear wheel Spring preload
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 shock absorber, adjusting . . . . . . . . . . . . . . . . . . . . . . . 72
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Refueling
Steering head bearing play
fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Riding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
starting up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Steering lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
S Stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Seat Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
INDEX 189
T
Technical data
chassis . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . 169-171
chassis tightening torques . . . . . . . . . . . . . . . . . . 175-177
engine . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . 164-165
engine tightening torques . . . . . . . . . . . . . . . . . . 166-168
fork . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . 172
shock absorber . . . . . . . .. . . . . . . . . . . . . . . . . . 173-174
Tire air pressure
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Tire condition
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151-153
Type label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
U
Use definition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
V
View of vehicle
front left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
rear right side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
W
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Work rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
*3211360en*
3211360en
11/2008 Photo: Mitterbauer
KTM-Sportmotorcycle AG
5230 Mattighofen/Austria
http://www.ktm.com

690 Enduro R Usa Manual

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690 Enduro R Usa Manual

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OWNER'S MANUAL 2009

690 Enduro R USA

We wish you great pleasure riding the vehicle!

Enter the serial numbers of your vehicle below.

Engine number ( p. 25)

Key number ( p. 25)

© 2008 by KTM-Sportmotorcycle AG, Mattighofen Austria

ISO 9001(12 100 6061)

MEANS OF REPRESENTATION ............................................... 7 Setting the clock .............................................................. 35

SERVICE PLAN .................................................................... 59 Checking chain dirt .......................................................... 79

AUXILIARY SUBSTANCES................................................... 182

Indicates an unexpected reaction (e.g. of a work step or a function).

Identifies a page reference (more information is provided on the specified page).

Name® Identifies a protected name.

Brand™ Identifies a trademark.

Fuel, oils, etc.

Spare parts, accessories

– Switch off the engine and remove the ignition key.

Overview of warning labels

1 Type label, Canada

Information, suspension setting

Information, chain tension

Information, fuel evaporation system

Information, putting into operation

Reporting safety defects

Noise emission warranty

Warning, operating noise

View of vehicle, front left side

1 Hand brake lever

View of vehicle, rear right

The chassis number  is stamped on the steering head on the right.

The key number  can be found on the KEYCODECARD.

Fork part number

Shock absorber part number

The clutch lever  is fitted on the left side of the handlebar.

Hand brake lever

The light switch  is fitted on the left side of the handlebar.

The flasher switch  is fitted on the left side of the handlebar.

The horn button  is fitted on the left side of the handlebar.

Emergency OFF switch

Emergency OFF switch on – This position is necessary for operation as the

Electric starter button

The ignition/steering lock  is located in front of the seat.

The combination instrument is installed in front of the handlebar.

Combination instrument - function buttons

You can change the display mode with the M button .

Combination instrument - indicator lamps

Temperature warning lamp lights up red – Coolant has reached a critical

The idle speed indicator lamp lights up green – The transmission is

FI warning lamp (MIL) lights/flashes orange – The OBD has detected an

Combination instrument - display

The display then changes to the last selected mode.

Combination instrument - speedometer

Setting kilometers or miles

– Switch on the ignition by turning the ignition key to position ON .

Combination instrument - time

The time is shown in area  of the display.

Setting the clock

– Switch on the ignition by turning the ignition key to position ON .

Combination instrument - display ODO

Combination instrument - setting/resetting TRIP 1

– Switch on the ignition by turning the ignition key to position ON .

Combination instrument - setting/resetting TRIP 2